Patent Application
20180094230
This application claims priority from European Patent Application No. 16425093.8, filed on Sep. 30, 2016, which application is incorporated herein by reference in its entirety.
The present invention relates to a device and method of heating/bending/forming and heating/toasting barrels, casks, vats and the like for refining, conditioning and ageing alcoholic beverages and other foods.
As is known, in the field of alcoholic beverages and wine in particular, but also in general of foods, the phase of refining, conditioning and ageing alcoholic beverages, typically, but not exclusively wine, in special barrels, casks, vats and the like is increasingly requested. The wood is in fact able to transfer by contact to the alcoholic drink (and in general to the food) a highly complex aromatic content which enhances the final product. The aromatic components that wood is able to transfer to the beverage are varied and depend on many factors, the first being the type of wood used to make the container/barrel in which the drink is contained, as well as, for example, the length of contact, namely the length of ageing, the ratio of the volume and contact surface area of the container and the beverage, and so forth. It is also possible to change, at least partially, such aromatic content enriching it with toasting components (often referred to as tertiary aromas) obtained by toasting the inner wall of the container destined to come into direct contact with the food.
Toasting the wood is a very delicate and complex phase and is one of the most important steps in making a barrel for ageing.
In particular, the construction of the barrel goes through several steps that can be summarised as follows:
selection of the wooden boards,
shaping of the staves,
assembly of the barrel with arrangement of the staves in a circle,
heating and bending to achieve the desired shape,
heating and toasting,
closure of the barrel with the bottom.
The phases relevant to this invention are those of heating, bending/forming and heating/toasting.
The step of bending/forming the wood plays an important role in giving the barrel its distinctive curved shape and ensuring the mechanic and hydraulic resistance of the finished product. Clearly the bending of hardwood boards of a thickness of 25-100 mm is a very delicate step which can cause the board to break.
This step is performed by heating the circle of staves of the barrel in order to exceed, throughout the thickness of the staves, the temperature of 40-45° C. (which corresponds to the glass transition temperature of cellulose, the main constituent of said stave). At the same time bending/forming is performed in stages to allow the wood to slowly adapt and to stabilize in the bent form, this too aided by the heat.
The heating step is traditionally performed by lighting a fire, confined in a brazier, fed for example with production scrap of the same wood forming the barrel. Clearly this technique requires continuous monitoring by an operator to avoid high temperature swings or superficial burning of the wood. Over time in the art other techniques have been developed, based on alternative and adjustable heating systems such as gas flames, electric heaters, infrared lamps and lately the use of chips or wood pellets. As an alternative, techniques have also been developed which contemplate the use of water both in liquid form (immersion) and in steam form (entire barrel in chamber with flowing or pressurised steam).
These latter options provide greater uniformity of heating and machinability of the wood but can lead to major losses of the extractable fraction (aromas and tannins) with loss of quality of the finished product. In addition, for large barrels it becomes difficult if not impossible to move or contain them in closed chambers.
During this step, or subsequently, bending is performed with the help of jaws, powered by jacks and levers, which tighten the barrel while keeping the centre fixed or with the use of tie-rods (metal cables that wrap around the base of the barrel) moved by jacks; in the latter case the centre of the barrel migrates, following the direction of pulling. The fact that the centre of the barrel is not fixed involves having to move the heat source to keep it equidistant from the inner surface of the barrel. The system with pulling cables proves more flexible in relation to the various diameters of the barrels and to the shape of the barrel itself (circular or elliptical). By contrast the jaw system is preferable for the production of e a limited number of shapes and sizes of barrels.
In part overlapping such step or, possibly, subsequently, is the toasting phase which defines the characteristics of the finished barrel in relation to the type of aromas to be obtained. At this stage accurate temperature control becomes crucial to make the barrel characteristics repeatable. In manufacturing, the terms light, medium and strong toasting with possible intermediate classes, are used.
From the above description it is clear how control of the temperature during toasting is essential in order to achieve a toasting over the entire inner side wall of the barrel; in fact, even a temperature variation of about 5% can result in uneven heating and toasting determining a highly variable quality of the finished product.
Temperature control during toasting is therefore essential; the problem is accentuated when the barrel is not toasted, as seen after its forming, but during the bending of the staves with tie rods. In fact, the geometric centre of the barrel being formed changes constantly in relation to the geometric centre of the brazier, leading to a variation of the distances between the heat source (brazier) and inner side wall to be bent. This change causes an unevenness of the temperature on the inner side wall of the barrel prejudicing correct bending and/or causing unwanted toasting.
Besides, such off-centredness is very difficult to detect because the barrel itself obstructs the view from the outside of an operator monitoring the bending and/or toasting process.
To avoid this kind of problem solutions have been developed that provide for the toasting of a barrel already formed, therefore having a fixed centre not variable over time. This way, however, the solution is not very versatile in that it does not provide for possible contemporary bending and toasting. If the heating/bending and the heating/toasting are performed separately, the total time of manufacture/toasting the barrel increases since it is given by the sum of the time of forming and of toasting the barrel. Accurate temperature control of the side wall inside the barrel is essential since it may be necessary to perform the toasting at relatively low temperatures for a long time (so as to have a strong penetration of heat inside the staves) or at higher temperatures for a shorter time (strong surface treatment of the wood). In other words, the time and temperature are a function of the thickness of the staves constituting the barrel and of the desired features to be obtained.
In light of the above, it is clear that the known solutions do not ensure optimal bending/toasting, given the variations in the thickness of the wood constituting the staves and, at the same time, a reduction of manufacturing times and costs of a toasted barrel for ageing drinks or other foods.
The purpose of the present invention is to make a device and/or method which overcome the drawbacks mentioned with reference to the prior art.
Such drawbacks are resolved by a device according to claim 1 and by means of a method according to claim 18.
Other embodiments of the present invention are described in the subsequent claims.
Further characteristics and advantages of the present invention will be more clearly comprehensible from the description given below of a preferred and non-limiting example of embodiment, wherein:
With reference to the aforementioned figures, reference numeral 4 globally denotes a heating/bending/forming and heating/toasting device of wooden containers 8 for the refining, conditioning and ageing of foodstuffs, such as alcohol. Typically, but not exclusively, the invention applies to the heating/bending/forming and heating/toasting of barrels, casks, vats and the like 10 for ageing wine. Obviously the invention applies to the refining, conditioning and ageing of foods in general, not necessarily liquids, such as solid foods, and not necessarily alcoholic beverages, such as vinegar and the like.
Said heating/bending/forming and heating/toasting device of barrels, casks, vats and the like 10 comprises heating/toasting means 12, typically a brazier, suitable to generate heat to produce heating and/or toasting of an inner side wall 16 of a barrel, cask, vat or the like 10, said barrel, cask, vat or the like 10 comprising a plurality of staves 20 arranged side by side along the perimeter with each other to form a polyline closed at a first longitudinal end thereof 24. Typically said polyline is a circle. The heating/toasting means 12 typically comprise a brazier which can be fed with wood, pellets and the like, gas or other sources of heat.
Preferably, the brazier has an axial symmetric shape so as to provide even and symmetrical heating and therefore toasting on said inner side wall 16.
The heating/bending/forming and heating/toasting device 4 further comprises bending/forming means 28 of said staves 20 suitable to grasp free ends 36 of said staves 20 opposite said first longitudinal ends 24, and to pull the staves 20 towards a central axis of symmetry S-S of the barrel, cask, vat or the like 10. The free ends 36 are opposite the first longitudinal end 24 along a main axis of longitudinal extension of the staves 20.
For example, said bending/forming means 28 comprise ropes, preferably metal, which circumferentially enclose the staves 20 from the side of the free ends 36 so as to close them towards the inside of the barrel, cask, vat or the like 10, i.e. towards the central axis of symmetry S-S. The bending/forming means 28 comprise appropriate motor means for tensioning for example the ropes, so as to bend the staves 20 as required.
Of course, for the purpose of the present invention other bending/forming means 28 may be used.
Advantageously, the heating/bending/forming and heating/toasting means 4 comprise centering means 40 operatively connected to the heating/toasting means 12 and suitable to be operatively connected to the staves of the barrel, cask or the like 10, on the side of the free ends 36 of the staves 20 opposite the first longitudinal ends 24.
Advantageously, said centering means 40 move the heating/toasting means 12 to said central axis of symmetry S-S of the barrel, cask, vat and the like 10.
In particular, this means that thanks to the centering means the central axis of symmetry S-S of the barrel, cask, vat or the like 10 tends to coincide with an axis of symmetry of the heating/toasting means 12, i.e. of the brazier.
According to a possible embodiment, the centering means 40 comprise spacers 44 that guarantee the same distance D between an inner side wall 16 of the staves 20 facing the heating/toasting means 12 and the heating/toasting means 12 themselves. The term same distance D means that thanks to the spacers 44 the heating/toasting means 12 are placed equidistant from the inner side wall 16 of all the staves 20 so as to heat and toast the staves evenly and continuously. In other words, thanks to the spacers 44, the heating/toasting means 12 are always placed in the theoretical centre, i.e. along the central axis of symmetry S-S of the barrel, cask, vat and the like 10.
According to one embodiment, the spacers 44 are adjustable so as to follow the deformations of the staves 20 during the bending thereof, continually bringing the heating/toasting means 12 to said central axis of symmetry S-S of the barrel, cask, vat or the like 10.
According to one embodiment, the spacers 44 comprise elastic portions 48 suitable to adapt to the bending/deformation of the staves 20 so as to modify the distance between the staves 20 and the heating/toasting means 12, ensuring the positioning of the heating/toasting means 12 at said central axis of symmetry S-S of the barrel, cask, vat or the like 10.
For example, the elastic portions 48 may comprise springs and/or retractable portions comprising a sheath worn on a corresponding stem, so as to lengthen or shorten during the deformation of the staves 20.
According to one possible embodiment, the spacers 44 are configured to be placed between the heating/toasting means 12 and the inner side wall 16 of the staves 20 facing the heating/toasting means 12.
According to a further embodiment the spacers 44 are placed on the side of an outer side wall 52 of the staves 20, opposite the heating/toasting means 12, and are operatively connected to the heating/toasting means 12.
The connection between the spacers 44 and the staves 20 may be made, for example, through the use of brackets 56 hooked to a lower edge 60 of the staves on the side of the free ends 36.
Preferably the brackets 56 hook to said lower edge 60 so as to realize an undercut in both directions, away from and towards the central axis of symmetry S-S, so to follow every movement of the staves 20, both in expansion and contraction, under the effect of the bending/forming means 28.
According to a further embodiment, said brackets 56 are fixed/hooked to the outer side wall 52 of the staves 20.
According to a preferred embodiment, the heating/toasting means 12 are mobile so as to adapt to the deformation of the staves 20. For example (
For example, the heating/toasting means 12 are provided with support wheels on a support plane, so that they can be dragged under the thrust of the centring means 40.
According to one embodiment, the spacers 44 comprise springs and/or adjustable pistons suitable to ensure the positioning of the heating/toasting means 12 at said central axis of symmetry S-S of the barrel, cask, vat or the like 10.
According to one possible embodiment, the centering means 40 comprise at least three spacers 44 placed equidistant at angles of 120° to each other.
According to one embodiment, the device 4 of the present invention comprises at least one temperature sensor 64, integral with the heating/toasting means 12, said temperature sensor 64 being directed towards an inner side wall 16 of the associable staves 20 so as to measure the surface temperature of said inner side wall 16 of the staves 20 at a distance.
Preferably, said temperature sensor 64 is an infrared temperature sensor, so as to be able to measure the temperature of the staves 20 remotely.
For example, the heating/toasting means 12 comprise a base 68 above which the heat source for heating/toasting the barrel, cask, vat or the like propagates, for example extending a flame; the temperature sensor 64 is placed below the base 68 and integral therewith.
Preferably said base 68 is provided with at least one window 72 at least partially aligned with said temperature sensor 64 to allow the crossing of the base 68 by a beam of infrared rays emitted from the inner side wall 16 of the staves 20 remotely striking the temperature sensor 64.
Preferably, the temperature sensor 64 is associated with the heating/toasting means 12 by adjustable support means 76, so as to be able to vary the inclination of the temperature sensor 64 to strike appropriate portions of the staves 20.
The heating/bending/forming and heating/toasting method of barrels, casks, vats or the like according to the present invention will now be described.
In particular said method of heating/bending/forming and heating/toasting barrels, casks, vats or the like comprises the steps of:
According to one embodiment, the method further comprises the steps of:
Preferably, the method of heating/bending/forming and heating/toasting barrels, casks, vats or the like according to the invention also comprises the step of associating the temperature sensor 64 with the heating/toasting means 12 by adjustable support means 76, so as to be able to vary the inclination of the temperature sensor 64 to strike appropriate portions of the staves 20.
In particular, an example of variation of the inclination of the temperature sensor 64, thanks to the adjustable support means 76, depending on the different dimensions of the barrel, cask, vat and the like is shown schematically in
Moreover,
As may be appreciated from the description, the device and method of the present invention make it possible to overcome the drawbacks of the prior art.
In particular, the solution permits the heating/bending/forming and heating/toasting steps of the barrels, casks, vats or the like to be performed at the same time, so as not to increase the production cost and time of the barrels, casks, vats or the like.
Advantageously, the device is provided with a self-centering system in bending/forming/toasting, which makes it possible to continually centre the brazier always placing it in the geometric centre of the barrel, cask, vat or the like during the contingent bending step.
Any alteration of the geometry of the barrel, cask, vat or the like in bending/forming is detected by the centring system which continuously aligns the brazier in the geometric centre of the barrel, cask, vat or the like gradually being formed. The brazier is advantageously movable under the guidance/thrust of the centering system.
In addition, the device advantageously provides for control of the temperature reached on the inner side wall of the barrel, cask, vat or the like by means of an appropriate temperature sensor that provides a signal which can modify the process parameters.
In particular, the positioning of the temperature sensor under the brazier, and integrally therewith determines a number of advantages.
For example, it avoids the constant centering of the temperature detection system depending on the size of the barrel, cask, vat or the like in the heating/bending/toasting step thanks to the fact that the detector is placed under the plane of the brazier with an inclination such as to permit a reading which is not affected by the naked flame and at the same time is correct for different sizes of barrels, casks, vats or the like.
Moreover, thanks to the fact that the temperature sensor is integral with the brazier, the movements of the brazier do not change the reading conditions.
In addition it makes for a greater ease of movement of the barrels, casks, vats and the like in production since there are no external obstructions due to the positioning of sensors in the area above the work surface, as occurs in the solutions of the prior art. Said obstructions are especially critical for barrels, casks, vats and the like of medium-large size and difficult to handle.
Furthermore, the provision of a single inclination of the temperature sensor, and in any case adjustable, provides extreme versatility for making format changes on the same heating-bending-toasting workstation.
Overall, the present invention enables the migration of the brazier fire point and therefore the conservation of equidistance of the brazier with respect to the inner surface of the barrel, cask, vat or the like. Such equidistance ensures a uniform heating and thus toasting of the entire inner side surface of the barrel, cask, vat or the like.
Therefore, the heating/toasting means, such as the burner, are fitted with wheels and integrated with the infrared temperature sensor/measuring device capable of reading an area representative of the temperature inside the barrel, cask, vat or the like, and with a dragging system of the brazier, achieved by centering means, in order to maintain the centering of the same in relation to the migration of the centre of the barrel, cask, vat or the like by tensioning of the cables used for bending the staves.
With the present invention it is possible to obtain an extreme versatility with respect to the size of the barrel, cask, vat or the like which can be highly variable according to the demands of users: ranging from an approximately 225-litre barrel to over 100 hectolitres.
Furthermore the creation of an integrated monobloc is achieved comprising the heating system, monitoring and management of temperatures and migration of the heating point utilisable for barrels, casks, vats or the like of different formats without changing the settings, alignments or other features: this way an extreme versatility is achieved for use on wood containers of different shapes and sizes.
A person skilled in the art may make numerous modifications and variations to the devices and methods of bending/forming and heating/toasting described above so as to satisfy contingent and specific requirements while remaining within the sphere of protection of the invention as defined by the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 16425093.8 | Sep 2016 | EP | regional |
