Patent Application
20180327129
This application is related and claims priority to GB 1706306.6, which is hereby incorporated by reference in its entirety for all purposes.
The present invention relates generally to a cold filling process for the filling of beverages into a packaging comprising an interior drinking straw and a system for performing such process.
One key factor in the customers' perception of a product in the consumer goods sector is convenience. This statement is especially true for market situations, wherein supplier dependent quality differences of the good itself are difficult to detect or many alternatives or substitute products can be found. In such cases, it is frequently helpful to add secondary benefits to the product at hand for differentiation. Such strategy can for instance include a special packaging design, offering the consumer the possibility of a different and easier, i.e. more convenient, product use.
In the field of foodstuff, such differentiation is also feasible, but the freedom in packaging design is, compared to other product classes, limited, because the most important task of the packaging is to guarantee the food safety over the defined minimum durability. This side-condition limits the overall amount of possible packaging solutions and restricts the choice to solutions only, which are able to guarantee microbiological safety.
Such considerations are especially important in the field of beverages. Beverages usually comprise high water activity, leading to excellent microbiological growth conditions. Hence, the products are very sensitive with respect to the packaging and the packaging process and alternative solutions comprising additional benefits with respect to the usability are rare.
One attempt to provide alternative drinking applications is the supply of a separate drinking straw to a beverage packaging. The straw provides a more hygienic and convenient drinking situation and is usually assembled in an independently packaged form at the outside of a beverage container. Due to the fact that both parts are individually packed it is possible to separate the production process and treat the microbiological side-conditions in processing and during storage of both parts independently.
Other technical solutions for beverages concern a situation, wherein a straw is included inside the beverage packaging.
U.S. Pat. No. 6,854,490 B2 for instance disclose a flexible pouch with a self-contained straw for packaging a product, wherein the pouch includes a front panel and a back panel each having an upper edge, a lower edge opposite the upper edge, and side edges extending there between the upper and lower edges.
Another technical solution is described in EP 0 997 393 B1. In this patent document, a packing sachet with a drinking straw or pouring tube arranged in the sachet and an easy-opening protected area as access to the straw or pouring tube is disclosed, where the sachet has a first compartment to hold a filling and a second compartment separated fluid-tight from the first by a sealing or adhesive seam and intended to hold a straw part.
The integration of a straw in the beverage packaging generates a safer application because the straw cannot unintentionally be separated from the beverage packaging. Unfortunately, the microbiological situation of the beverage changes completely because the straw has to be fully considered in the microbiological background of the beverage and during beverage packaging. This severely limits the available packaging solutions and the suitable packaging processes. Based on safety consideration for the latter only hot-fill processes are state of the art. In such hot-fill processes the beverage is sterilized by heating up to temperatures suitable for killing microorganisms in the beverage and the heated beverage is also used to sterilize the beverage packaging and the included straw. Only the filling at high temperatures assures a clean microbiological background and sufficient shelf life. Unfortunately, this process is very energy-intensive, limited to batch processing and the thermal load on the beverage and the packaging is high, resulting in degradation of valuable ingredients or deterioration of the taste.
Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
It is the task of the present invention to disclose a packaging process and a system for performing such process, being able to overcome the shortcomings of the prior art and to provide a safe and economic packaging process, especially directed to the filling of beverage packaging containing an interior drinking straw.
Above mentioned task is fulfilled by a process for filling of beverage packaging comprising an interior drinking straw, characterized in that the filling process at least comprises the steps of
a) In-line microwave assisted pasteurization of the beverages,
b) Vaporized Hydrogen Peroxide treatment of the packaging,
c) Vaporized Hydrogen Peroxide treatment of the straw,
d) Assembly of the Vaporized Hydrogen Peroxide treated straw in the Vaporized Hydrogen Peroxide treated packaging,
e) Fixation of the straw inside the packaging,
f) Temperature adjustment of the pasteurized beverage of step a) and cold filling of the pasteurized beverage into the hydrogen peroxide treated packaging including the fixed straw, and
g) Sealing of the packaging.
Surprisingly, it was found that it is possible to achieve a microbiological safe and convenient packaging solution, wherein a straw is securely integrated inside the beverage packaging, by using above described process. It is especially possible to avoid state-of-the art hot-fill processes, resulting in an overall economic filling and packaging process, wherein the thermal load on the product is significantly reduced. In consequence, the same or even better microbiological safety levels and minimum storage lifes can be achieved and, at the same time, the packaged beverages comprise higher nutrient levels, based on the reduction of the thermal stress during packaging. In addition, it is possible to achieve better taste levels of the beverages, even at reduced sugar contents, rendering the product healthier compared to standardly processed beverages. The energy consumption of the overall process is much lower compared to the state of the art processes and further, some of the energy can even be recycled within this process. In hot fill processes, the energy is lost because it is technically difficult to cool the single packaging after filling. In the now proposed process, it is possible to transfer heat from the beverage product stream before filling because the filling temperature of the beverage into the packaging is not the microbiology determining step any more. Therefore, the energy costs are significantly reduced, i.e. in the range of approximately 50% compared to a hot fill process of the same product output. Furthermore, better recyclable packaging material can be used, which cannot be processed under hot-fill conditions. The overall water consumption can be reduced because it is not necessary to significantly cool the product after the filling process. An additional advantage is that the processing can be significantly faster because the cooling time of the packaged beverage can be reduced. The cold filling is especially possible from 4-5° C. up to ambient temperature. Furthermore, the microwave pasteurization results in a more homogeneous temperature profile throughout the beverage, leading to better microbiological kill rates and a more uniform product after pasteurization. The overall process is more environmentally friendly and at the same time a greener product with a better carbon footprint becomes available.
The filling temperature can be freely adjusted and can even be set to the necessary storage temperature of the packaged beverage. Therefore, no additional waiting period or other temperature adjusting means are necessary between packaging and storage. This keeps the overall process very fast and energy efficient. Furthermore, it is possible to re-formulate the beverage composition because the beverage composition is usually adjusted with respect to the process. In hot-fill processes, additional flavor carriers are sometimes added to the beverages in order to compensate for the flavor loss in packaging. In the now proposed process, this is unnecessary and, as a consequence, healthier beverages can be offered, wherein the salt or sugar content is reduced compared to standard beverages being obtained by hot-fill processes. In addition, the proposed process is environmentally friendly because no toxic chemicals are used in the process.
According to the invention, a process for filling of beverage packaging is disclosed, wherein the process is especially suitable for industrial filling at high speeds. Beverages in the sense of this invention are all kinds of liquids suitable for human consumption. The process mainly concerns the filling of the beverage into the packaging including a straw and the necessary pre-steps on the packaging material and the liquid in order to achieve a microbiological safe product in the packaging. It is particularly not intended to provide a process, wherein the microbiological status of the beverage or the packaging is adjusted by physical means after the filling process.
The packaging according to the invention comprises an interior drinking straw inside the packaging. This means, that the beverage packaging also surrounds the drinking straw and the beverage and the drinking straw is accessible at the same time after only opening one packaging. The latter may be achieved for instance by tearing the beverage packaging at one point.
In step a), the beverage is pasteurized microwave assisted and in-line. This process steps particularly excludes the use of pure thermal means (like steam or resistance) for beverage heating. The pasteurization is achieved by using high frequency microwaves, e.g. around approximately 2.450 MHz; for treatment of a beverage stream. The microwaves induce an even and fast thermal heating of the beverage and is able to reduce the microbiological load. This step may be achieved by passing the beverage stream through a microwave transparent pipe (e.g. based on Teflon), which is surrounded by one or more microwave generators. Based on the beverage flow speed, the desired temperature, the amount of microwave generators and their power settings, the resulting temperature of the beverage stream can be set. Suitable microwave heating times can be up to 30 seconds and suitable temperatures of the beverages can go from 10-15° C. degrees up to 76-80° C. Within these time and temperatures ranges, a log reduction of 3-5 is achievable for the beverages.
In a second step b), the packaging is treated by Vaporized Hydrogen Peroxide (VHP). This means that the packaging material is contacted with vaporized hydrogen peroxide for a certain time period. The packaging material is either treated in the form of the final packaging or in the form of a pre-material, e.g. a film, which is converted to a pouch following the peroxide treatment. The efficiency of the Vaporized Hydrogen Peroxide treatment can principally be adjusted as a function of the vaporized hydrogen peroxide concentration and the contact time. Generally treatment times can be in the range of seconds. Such VHP treatment speeds enables the set-up of high throughput filling lines, wherein easily more than 100 packages/minute are producible. The hydrogen peroxide may be food grade H2O2 solution (35%). As a function of the packaging material and the treatment conditions, principally sterile packaging material can be provided to the filling step. Nevertheless, in certain cases it might be sufficient not to achieve a completely aseptic material, but instead to achieve only a log reduction (e.g. 3-5) in microbiological counts of the packaging and the beverage, respectively. Also, these situations are in the scope of this invention.
In step c), the straw is treated by Vaporized Hydrogen Peroxide. Surprisingly, it was found that it is possible to obtain within suitable reaction times an essentially clean straw material. This is surprising because straws exhibit an unsuitable geometry for the hydrogen peroxide diffusion and it was assumed that it is difficult to assure proper sterilization in the field of foodstuff without further technical measures. Nevertheless, it is possible to achieve either sterile or nearly microbiological clean material at moderate peroxide concentrations and reaction times.
In step d), the Vaporized Hydrogen Peroxide treated straw is assembled in the Vaporized Hydrogen Peroxide treated packaging. The assembly may be performed on a 1 to 1 basis in the meaning that one packaging and one straw is sterilized within the filling chamber and both are assembled. It is also feasible to perform the peroxide treatments on a number of packaging and/or straws and to store the vapor treated material in the meantime before the straw and the packaging is assembled. The assembly can be performed by known technical means and may usually be achieved by placing the straw in a certain position relative to the packaging.
In step e), the straw is fixed inside the packaging. The fixation of the straw inside of the packaging may be achieved by processes which are able to assure that the straw is attached to the packaging and keeps in position during the filling process. This may e.g. be achieved by pure physical forces between the packaging and the straw or by heat sealing the straw onto the packaging material.
In step f), the pasteurized beverage obtained in step a) is temperature adjusted and cold filled into the hydrogen peroxide treated packaging including the fixed straw. The temperature adjustment of the pasteurized beverage can be achieved by techniques known to the skilled artisan. In certain cases, it can be performed by heat exchanging means like a plate heat exchanger. Suitably, the temperature of the beverage is adjusted to a temperature from 5° C. up to 20° C. in order to maintain the valuable nutrients like the vitamins of the beverage intact. Furthermore, the adjustment of the temperature and especially the cold filling process will speed up the overall assembly and packaging process because either different packaging material (e.g. with lower heat resistance properties) can be used or no extra waiting time has to be included in the process in order to achieve the right temperature at the different packaging steps.
Finally, the packaging including the beverage and the fixed straw is sealed in step g). The sealing of the packaging can be achieved by means known to the skilled artisan. This may for instance either be heat sealing of a packaging film or by screwing a cap or a septum onto the packaging. The only technical requirement can be seen in that the last step has to assure that the packaging inside is at least microbiologically separated from the outside.
In a preferred embodiment, the Vaporized Hydrogen Peroxide treatment of the packaging and the straw in step b) and step c) is performed in-line and the Vaporized Hydrogen Peroxide treatment is a hydrogen peroxide dry gas process. A dry gas process means that the hydrogen peroxide is vaporized under conditions, wherein the vapor is essentially prevented from re-condensing. Therefore, it is possible to work with low hydrogen peroxide concentrations resulting in low costs. In addition, this dry gas process might reduce the negative impact of the sterilization treatment on the packaging material.
In a further characteristic of the process, the microwave assisted pasteurization in step a) is performed at a temperature of ≥70° C. and ≤100° C. for a time period of ≥20 seconds and ≤150 seconds. Within this temperature and time range, the beverages can be pasteurized in a fast and gentle manner, resulting in a better flavor and higher nutrient content after pasteurization.
In another aspect of the invention, in step f) the energy obtained by the temperature adjustment of the beverage is used to adjust the beverage temperature before the microwave assisted pasteurization in step a). In order to obtain a cold fill process, in general, it is suitable to cool the beverage after the pasteurization step before filling the packaging. The excess heat can be transferred to a cooling liquid and the heated cooling liquid can be used to pre-heat the beverage before the microwave assisted pasteurization step. In this embodiment, the overall energy needed for the microwave step is reduced because some of the temperature is already provided by the pre-heated cooling liquid. This process exhibits lower energy costs at an uncompromising food safety level. Hence, this process is especially more efficient compared to a hot-fill HPP process and more environmentally friendly. In a preferred embodiment, at least 20%, preferably 30% of the energy needed in the pasteurization step is provided via heat exchange from later process stages.
In a further embodiment, the cold filling is performed at a beverage temperature of ≥5° C. and ≤25° C. Within this temperature range in step f), it is additionally possible that the end product is transferred to a warehouse storage without any time delays. For instance, it is possible to load the product directly into a lorry. The product can be handled or packed into lower grade environmentally friendly carton packaging. The carton design will not suffer any dew point or temperature compatibility problems and a step towards an environmentally friendlier and cheaper packaging is possible. In addition, in comparison to a conventional hot filling process, wherein the filling is performed at ≥78° C., such process does not require water bath usage and cooling tunnels in order to reduce the temperature below e.g. ≤40° C.
In another characteristic of the process, the packaging may be selected from the group consisting of pouches, flexible stand-up pouches, bottles, jars, sachets and cans. Especially this class of packaging material has been found suitable for the inventive process because the materials are compatible with the VHP integrated treatment. This results in long shelf lives of the packaged product even under non-chilling conditions.
Within a preferred aspect, the packaging used in the disclosed packaging process is a pouch. Particularly pouches are compatible with the described process. This is mainly based on the fact that it is possible to separate the material sterilization from the pouch formation. It is for instance possible to sterilize a film laminate by the dry gas process and to form the pouch after the vapor treatment step. In this case, a simple straight surface can be exposed to the hydrogen peroxide vapor. This avoids situations, wherein complicated pouch geometries has to be sterilized and extra care has to be taken to assure, that also deep pouch cavities get in sufficient contact with the peroxide gas. Therefore, the VHP gas treatment can be performed easier and at shorter process times.
In another embodiment of the invention, the pouch may be made from a laminated film structure, wherein at least one film layer of the laminated film structure is selected from the group consisting of Linear Low Density Polyethylene (LLDPE), Metallocene Linear Low Density Polyethylene (MLLDPE), VLDPE (Very Low Density Polyethylene) or Metallocene Very Low Density Polyethylene (mVLDPE) films. This group of film material is very compatible with the proposed hydrogen peroxide sterilization step and also offers additionally advantages in the cold filling step. The surfaces of the film material can be sterilized with the Vaporized Hydrogen Peroxide very fast. The latter sealing step can be performed quicker compared to hot-fill processes because film temperatures are lower and the sealing can be performed under different temperature conditions. This might lead to an overall improvement in the packaging output. Furthermore, these film materials are recyclable, increasing the ecological and environmental friendliness of the process.
Within another aspect of the invention, the hydrogen peroxide dry gas process in step b) and c) is performed for a time period of ≥5 seconds and ≤100 seconds. This time period is sufficient to achieve excellent kill rates at fast processing times. It is further preferred to maintain in step b) and c) a temperature of ≥40° C. and ≤50° C. and to keep a contacting time period of ≥10 seconds and ≤25 seconds. In order to maintain sufficient hydrogen peroxide concentrations, it is possible to use hydrogen peroxide feeds of 1-12 g/minute.
In a further aspect, in step c), the hydrogen peroxide gas can be directed at least partly into the straw by active convection. In the case that packaging containing large beverage volumes are desired, it might be necessary to also include long straws. In order to assure short packaging times, it might be feasible to assist the hydrogen peroxide treatment especially of the straw by further blowing the vapor into the straw. This might increase the effective concentration of the peroxide per time unit. Therefore, the packaging line can be run faster without the risk of leaving the straw in non-sterile conditions. The active convection can for instance be achieved by a guided vapor stream, generated by a ventilator.
Within another characteristic, the beverages can be selected from the group consisting of water, flavored water, milk, juices, fruit juice, smoothies. Especially these beverages are prone to degeneration in the course of a hot-fill process. This might be attributed to the nutrient composition and content of the listed beverages. Therefore, it is advantageous to use a cold-fill process, wherein the processing time at higher temperatures can be significantly reduced.
Within a preferred embodiment of the process, in step e), the fixation of the straw to the packaging can be achieved by a dynamic induction heating process. By using induction heating in the framework of a cold-fill process it is possible to keep the overall filling speed up and additionally provide some temperature nearby the straw. This may further increase the microbiological safety of the straw surrounding, without deteriorating the beverage quality.
In another aspect, the straw may be made from PE, PP or mixtures thereof. Especially PE and/or PE can be used within the proposed sterilization process and deliver high log microbiological reductions rates even at very gentle hydrogen peroxide conditions and at short treatment times. In addition, no changes in the material properties are observed upon the hydrogen peroxide dry gas process.
Within a further aspect the straw may comprise a PE-layer and the pouch film may comprise a multi-layered structure at least comprising a polypropylene—(PP), an ethylene vinyl alcohol—(EVOH) and a polyethylene—(PE) layer. This means that the straw can be made from PE or may comprise a layered structure also comprising a PE-layer. Preferably, the straw may comprise an outer layer made from PE material. Inner layers may for instance be a paper layer or any other film material comprising a good recyclability. Surprisingly it was found that with such a layer structure or with a straw comprising only a single PE layer it is possible to achieve a high throughput process with an excellent microbiology. Such finding is not obvious because PE straws usually comprise not the right thermal stability and bend upon extrusion and also in hot-fill processes. The bending of the straw is disadvantageous because the bending hinders the sterilization process, especially in cases wherein gaseous sterilization means are used. The latter is the case in the inventive process. In addition, by using such straw structures it is possible to maintain high sealing speeds in the process and reliably and reproducibly induction heat seal the straw to the pouch material. Therefore, at high production rates a very low sealing failure level can be achieved by using a PE-straws, also reducing the production costs. In summary, the use of a PE straw is environmentally friendly and can increase the production rate of the process. A further preferred straw composition may comprise a 80:20 PE:PP blend. Such blend has also proven advantageous in production and, in addition, is a recyclable straw mix, belonging to recycle code 2 (UK) in the same group as food containers, dishware, compost bins, speed humps and gardening apparatus (compost bins, garden edging and plant pots). Such group is much better compared to standard pouches including straw applications, wherein the latter usually comprise aluminum layer structures, because code 2 material can readily be recycled to clothing or industrial fibres. The 80:20 mix straw material can also not be used in a hot-fill process because it was found that based on the thermal load on the straw either the straw material or the sealing will fail.
The pouch material can advantageously be a multi layered film material, wherein the film material does not comprise an aluminum layer. It was surprisingly found that a PP:EVOH:PE delivers in combination with the inventive production process excellent sterilizability, product shelf live and high production throughputs. Such finding is surprising because usually the performance of this layer combination in standard hot-fill processes is very low, exhibiting high failure rates and very bad sealing behavior. Therefore, the inventive process is able to process a greener and better recyclable material and the same time higher processing rates compared to standard hot-fill processes. Especially, it was found that the water, flavour and UV barrier properties of this film material after sealing and the overall oxygen, oil and chemical barrier properties are excellent. The sealing rates and the sealing quality by induction sealing in combination with a straw also comprising a PE layer are also very good, resulting in a streamlined production process. In addition, this pouch material enables superior laser cutting properties and it is possible to precisely perform a laser cutting of the pouch cap above the straw in order to guide only a partial tearing of the pouch cap. This is also possible at high processing speeds and result in an application, wherein after tearing a part of the pouch cap remains on the pouch. In consequence, only one pouch piece has to be recycled and the number of waste is reduced.
It is further within the scope of the invention to also provide a system for filling of beverage packaging comprising an interior drinking straw at least comprising
a) a microwave assisted pasteurization unit for pasteurization of beverages
b) a Vaporized Hydrogen Peroxide treatment unit for treatment of the packaging material and the straw,
c) a heat exchange unit for temperature adjustment of the pasteurized beverage before filling,
d) a cold filling unit and
e) an induction sealing unit for sealing the packaging.
This system is suited to perform the above described filling process and hence all advantages and process conditions described for the inventive process shall be deemed disclosed and applicable for the inventive usable system. The overall system can also be described as a MSCF-system (Microwave Sterilize Cold Fill-system). Especially, this system avoids a pre- or after burning effect on the liquid products, which may typically appear when the product is passing a conventional pasteurization system. By using such system, a fast and reliable beverage packaging comprising an interior drinking straw can be obtained, which in turn results in an efficient reduction of packaging costs. Furthermore, this system is also able to deliver the same amounts of beverage packaging at significantly reduced energy costs. The latter is especially true in comparison to state of the art hot-fill process. Therefore, the CO2-load for the packaging is smaller compared to the hot-fill process, rendering the overall process “greener”.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A preferred embodiment of the invention has been chosen for purposes of illustration and description and is shown in the accompanying drawings, wherein:
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
1 Pouch packaging
2 Drinking straw
5 drinking straw in a figure eight configuration
| Number | Date | Country | Kind |
|---|---|---|---|
| 1706306.6 | Apr 2017 | GB | national |
