ASEPTIC HOT-BREWED PACKAGED COFFEE OR ESPRESSO BEVERAGE

An aseptic, hot-brewed packaged coffee or espresso beverage is disclosed. The hot-brewed coffee or espresso beverage includes a beverage package comprising a hollow sterile container having a base and an outlet opening, the container having a beverage cavity. The aseptic packaged coffee or espresso beverage also includes an aseptic brewed coffee or espresso beverage having a solubles concentration of about 0.8% to about 2.0% and a solubles yield of about 14% to about 27%, the beverage partially filling the beverage, cavity to provide a filled portion and an unfilled portion. The aseptic packaged coffee beverage also includes a sealed closure, the sealed closure configured to maintain an aseptic environment in the unfilled portion of the beverage cavity.

DESCRIPTION OF THE EMBODIMENTS

Referring to the Figures, and more particularly toFIGS. 1-6, a packaged hot-brewed coffee beverage1is provided that has the taste and aroma attributes of freshly brewed coffee, but that has an extended shelf-life such that it may be sold and stored for extended periods with or without being refrigerated. The packaged hot-brewed coffee or espresso beverage1consists essentially of the coffee or espresso extracted by hot-brewing and the water used to make the extraction. In certain embodiments, the packaged hot-brewed coffee or espresso beverage consists essentially of the coffee or espresso extracted by hot-brewing, the water used to make the extraction and a flavorant. The packaged hot-brewed coffee or espresso beverage1does not include any milk products or natural or artificial sweeteners, or a combination thereof.

The packaged coffee beverage1includes a hollow aseptic or sterile container2having a base3and surrounding sidewalls20that extend upwardly and define a beverage cavity8and an outlet opening12. The beverage cavity8includes a filled portion14that holds or contains the coffee beverage4. The hollow sterile container2may have any suitable shape and size or capacity of the beverage cavity8. Suitable shapes and sizes include all manner of conventional beverage container shapes and sizes, including those generally used for individual portion beverages, such as those having a capacity of 2 to 32 fluid ounces, as well as 0.5-1.0 l bottle configurations, for example, as shown generally inFIG. 1. Suitable shapes may also include those used for containers 2 large enough to hold multiple beverage portions, such as those having a capacity of 32 to 384 fluid ounces, as well as 1.0-3.0 l bottles or jugs, for example, including those having handles10to aid in pouring the beverage, as shown generally inFIGS. 2 and 3. In one embodiment, the beverage cavity8has a capacity of 2 fluid ounces to 20 gallons, and more particularly 6 fluid ounces to 384 fluid ounces, and even more particularly 8 fluid ounces to 128 fluid ounces. In one embodiment, the container2may have the shape of a beer or soda bottle and a capacity of 6 fluid ounces to 30 fluid ounces, and more particularly 12 fluid ounces to 24 fluid ounces, as shown generally inFIG. 4. Larger sterile bulk containers may also be used. Any suitable shape and size sterile bulk containers may be used, including those having a capacity of about 2 up to about 20 gallons. Any suitable material may be used to make the sterile container2, including various glasses, ceramics, plastics, or metals, or a combination thereof. The material must be capable of undergoing temperatures sufficient to sterilize the coffee beverage and establish the aseptic environment without degradation, including treatment or cure temperatures from ambient up to about 250° F.

The packaged coffee beverage1includes an aseptic hot-brewed coffee beverage4comprising coffee and water, wherein the coffee is extracted from ground coffee beans by suitable hot-brewing process, as described herein. The hot-brewed coffee beverages4described herein may include those extracted by any suitable hot-brewing method, including methods that use liquid water at ambient pressure to produce coffee beverages, such as, for example, drip brewing, percolation, boiling. French-press, as well as methods that use liquid water and/or steam at pressures above ambient pressure (e.g. 9-10 atmospheres) for extraction, such as, for example, various espresso methods.

In one embodiment, where the hot-brewing method employs heated liquid water at ambient pressure, the hot-brewed coffee beverage4may have any suitable solubles concentration, including a solubles concentration of about 0.8% to about 2.0% and a solubles yield of about 14% to about 27%, and more particularly a solubles concentration of about 01.15% to about 1.5% and a solubles yield of about 18% to about 22%. The solubles concentration, solubles yield and other aspects of the hot-brewing process, such as, for example, the brewing ratio, may be measured in accordance with the standards set forth by the Specialty Coffee Association of America (SCAA). The hot-brewed coffee beverage4may be hot-brewed in any suitable brewing ratio of coffee and water, including being hot-brewed from coffee and water in a brewing ratio of 5 to 12 ounces of coffee per gallon of water.

In another embodiment, where the hot-brewing method employs liquid water and/or steam at pressures above ambient pressure for extraction. such as, for example, the hot-brewed beverage may comprise a hot-brewed espresso beverage4. Any suitable hot-brewing conditions may be employed to provide the hot-brewed espresso beverage4. The hot-brewed espresso beverage4has different characteristics, including a higher strength than a hot-brewed coffee beverage4because it employs higher extraction pressures and a much finer grind of the coffee, for example. While the hot-brewed espresso beverage4may be described with regard to a solubles concentration and yield, it is generally more desirable to describe the hot-brewed espresso beverage4with regard to a solids (including solubles) concentration and yield rather than a solubles yield, since the hot-brewing methods employed for espresso extraction provide a beverage with much higher amounts of undissolved coffee particles and emulsified oils. The hot-brewed espresso beverage4may have any suitable solids concentration, including a solids concentration of about 0.8% to about 2.0% and a solids yield of about 14% to about 27%, and more particularly a solids concentration of about 01.15% to about 1.5% and a solids yield of about 15% to about 25%. In addition, the hot-brewed espresso beverage4may have total dissolved solids of about 6% to about 35%, and more particularly about 8 to about 30%, and even more particularly about 11% to about 25%, and the total dissolved solids (i.e., coffee solids) in the water may vary as a function of the espresso brewing ratio, including the relative amounts of coffee and water employed during brewing.

The coffee used to hot-brew the coffee beverage may be from any suitable coffee bean, including Arabica or Robusta beans, or combinations thereof, and may include coffee beans grown in any country or geographic region of the world, such as, for example, Brazil, Vietnam, Columbia, Jamaica, Guatemala, Honduras, Mexico, Costa Rica, Ethiopia, Hawaii, India, or Indonesia, or combinations thereof. The coffee beans may have any suitable roast level, including light roast levels, such as cinnamon roast, New England roast and American roast that are roasted at low temperatures between about 383° F. to about 410° F., to heavy roast levels, such as French roast, Italian roast and Spanish roast that are roasted at high temperatures between about 464° F. to about 482° F. The roasted coffee beans may have any suitable grind, including extra-fine and fine grinds used for Turkish and espresso brewing, respectively, to medium-fine grinds used for vacuum pot brewing, and medium, medium-coarse and coarse grinds used for drip brewing and French press brewing, respectively.

The water used for hot-brewing the coffee to produce the hot-brewed coffee beverage4may be from any suitable water source, including various municipal or private water supplies. The water will preferably be selected to provide certain predetermined characteristics, including a predetermined mineral content, hardness, pH, alkalinity and sodium content, for use in the hot-brewing process and resultant hot-brewed coffee beverage4, since these characteristics will significantly affect the taste and visual characteristics of the beverage. Preferred water sources will include those having the predetermined characteristics described, preferably with limited chlorination or fluorination, and most preferably with no chlorination or fluorination. Spring water from a predetermined water spring is particularly desirable, including water springs having low water hardness. It is desirable that the water have a predetermined mineral content, including total dissolved solids (TDS) but that the mineral content not be so high as to result in precipitation or deposition of lime scale or other mineral deposits on the walls of the container over time during storage of the hot-brewed coffee beverage4in the container2. During the hot-brewing process solids are extracted from the coffee grounds and without consistent TDS levels, the quality of coffee and espresso can range greatly from strong and bitter to weak. Unless the TDS level is controlled, the consistency of the hot-brewed coffee beverage4will vary. In one embodiment, the water may have a predetermined amount of TDS between 50 ppm and 500 ppm, and more particularly 75 ppm to 250 ppm, and even more particularly 125 ppm to 175 ppm.

The water includes hardness ions, such as calcium and magnesium, that bind with the extracted coffee from the brewing process to give the correct flavor to the coffee or espresso beverage4. Minerals also help to reduce the acidity of water. Without the proper amount of hard minerals the hot-brewed coffee or espresso beverage4will have a high level of astringency or be very bitter. Therefore, the water should include a predetermined amount of hardness, particularly calcium, and in one embodiment should include calcium hardness of 1 to 5 grains or 17 mg/L to 85 mg/L.

The acidity and alkalinity of the water is very important to the taste of the hot-brewed coffee or espresso beverage4. A person with sensitive taste can notice a pH shift of as little as 0.1, so controlling pH is very important to beverage consistency and taste. Water below pH 7.0 is acidic and corrosive and water above 7.0 is basic and caustic. Higher pH also usually indicates a higher alkalinity and possibility of lime scale. In one embodiment, the pH is between 6.5 to 7.5, and more particularly between 6.7 and 7.3, and even more particularly 7. In one embodiment, the alkalinity is between 35 mg/L and 45 mg/L, and more particularly 40 mg/L.

The water should also have a predetermined sodium level to control the taste of the hot-brewed coffee or espresso beverage4. In one embodiment, the amount of sodium in the water is 10 mg/L or less, and more particularly 5 mg/L to 15 mg/L, and more particularly 8 mg/L to 12 mg/L, and even more particularly 10 mg/L.

The hot-brewed coffee beverage4may also include a flavorant that may be added before, during, or after brewing. Any suitable flavorant may be used to impart a predetermined flavor characteristic to the hot-brewed coffee beverage4. Suitable flavorants may include caramel, chocolate, white chocolate, brown sugar, cinnamon, gingerbread, hazelnut, almond, macadamia, walnut, vanilla, butter rum, butterscotch, chocolate, lemon, lime, orange, apple, banana, strawberry, raspberry, blackberry, blueberry, cranberry, lingonberry, cherry, pumpkin, spearmint, peppermint, Irish cream, amaretto, a liqueur, or other flavorant comprising alcohol, or a combination thereof. The flavorant, and the method of adding the flavorant will be selected to provide the desired flavor characteristic and be compatible with the hot-brewing process utilized, such that the flavorant does not react with the hot-brewed coffee beverage4so as to substantially diminish the appearance (e.g. by changing the appearance of the beverage by creating suspended particles to cause cloudiness or discoloration of the beverage) or storage life of the flavored, hot-brewed coffee beverage4.

The hot-brewed coffee beverage4is sealed within the sterile beverage cavity8using a sealed closure6that is configured to maintain the aseptic environment within the beverage cavity8. Referring toFIGS. 5 and 6, the sealed closure6includes a sealable cap22, such as a threaded cap24that is configured to be screwed onto a mating threaded structure26of the container2. The sealable cap22includes a seal28on its inner surface that is configured to seal against the rim30around the periphery32of the outlet opening20. The sealed closure6is configured to maintain an aseptic environment within the beverage cavity8, including both the filled portion14and the unfilled portion16. In one embodiment, the sealed closure6is a vacuum seal lid configured to maintain a vacuum seal in the unfilled portion16. In one embodiment, the vacuum seal lid is configured to provide an initial vacuum seal and is capable of being selectively removed and replaced once the initial vacuum seal is broken. In one embodiment, the sealed closure6is a single use closure. In another embodiment, the sealed closure is a multi-use closure. In one embodiment, such as that of the container2ofFIG. 4, the sealed closure6is a pry-off or twist-off crimped cap40. In one embodiment, the aseptic environment comprises a vacuum in the unfilled portion of the beverage cavity8. In another embodiment, the aseptic environment comprises a substantially oxygen-free gas in the unfilled portion, such that free oxygen is substantially zero. In one embodiment, the substantially oxygen-free gas comprises nitrogen. In another embodiment, the substantially oxygen-free gas comprises an inert gas, such as argon.

The packaged (i.e. aseptic, sealed) hot-brewed coffee beverage may be stored with or without refrigeration for an indefinite period, which more particularly may include zero to ten years, and more particularly one month to five years, and even more particularly one month to two years. Preferred storage conditions for extended storage are similar to those employed for the storage of other bottled beverages, particularly wine, including avoidance of exposure to direct sunlight to reduce the possibility of light induced reaction with the components of the coffee, and storage at near ambient temperatures, including temperatures of about 77° F. (25° C.) or less, and more particularly between 50° F. and 69° F., and even more particularly between 50° F. and 59° F.

Referring toFIG. 7, the production of the packaged hot-brewed coffee beverage1includes a method100of roasting110, grinding120, hot-brewing130, including separation or extraction and packaging140. A plurality of processes may be used for many of these steps dependent on the type of coffee desired and availability of equipment.

Roasting110includes exposing green coffee beans to heat as described herein, typically a pan or specialized bean roaster, until the bean color changes to a dark brown. The resulting bean will be approximately twice the size as a fresh bean, and for higher temperature roasts oil will appear on the outside of the bean.

Grinding120involves reducing whole roasted coffee beans into grounds or a grind. The size of the individual coffee grounds varies dependent on the preferred type of brewing as described herein. Several different types of machines and grinding processes may be used dependent on the desired size of the grounds, ease of grinding, and other factors. One suitable grinding method include Burr-grinding where the coffee beans are crushed or torn between two revolving wheels. Relatively little frictional heating of the beans is created. This process gives an operator a wide selection of particle sizes. Another suitable grinding method includes chopping where the coffee beans are sliced with metal blades spun at a high RPM (revolutions per minute). Particle size is not consistent making this method less desirable. Another suitable grinding method including pounding where the coffee beans are pulverized or crushed to a fine powder. This method is used to make grounds suitable for Arabic and Turkish coffee that require very fine coffee particles which are unattainable by most other forms of grinding. Yet another method includes roller grinding where coffee beans are ground between one or more corrugated rollers. This method also limits frictional heat and is desirable for large scale grinding operations.

Hot-brewing130may be performed by any suitable hot-brewing process. The hot-brewing method may vary dependent on the type of coffee desired and availability of resources. Types of hot-brewing include decoction (through boiling), infusion (through steeping), gravitational percolation also known as drip brewing, or pressurized percolation also referred to as espresso. During hot-brewing130extraction occurs as the water is forced to make contact with ground coffee beans either by gravity, steam or pressure. The solvable particles dissolve and pass through the filter changing the water into liquid coffee. Factors including temperature of water and amount of coffee grounds are controlled for optimum efficiency and taste. The temperature of the water used for hot-brewing coffee may range between 195° F. to 205° F., and more particularly between 200° F. to 205° F. at ambient pressure. Espresso may be hot-brewed by forcing hot water at between 195° F. to 205 ° F. under a pressure of between eight and fifteen bars (800-1500 kPa, 116-220 psi), through a lightly packed matrix, called a “puck,” of very finely ground coffee.

Packaging140includes filling142the filled portion14of the container2with the hot-brewed coffee or espresso beverage4, sealing144the container2with the sealed closure6and treating146the hot-brewed coffee or espresso beverage4, container and sealed closure6to provide an aseptic environment within the beverage cavity8. In order to ensure that the packaged hot-brewed coffee beverage1is aseptic, the hot-brewed coffee beverage4, container2and sealed closure6must be suitably treated to provide the aseptic sterile environment. In addition, it is essential to ensure that the steps used to treat the hot-brewed coffee or espresso beverage4, container2and sealed closure6do not degrade the taste or appearance of the beverage. Any suitable method of treating146the beverage, container2and sealed closure6may be used. However, because the hot-brewed coffee or espresso beverage4is already heated during the brewing process, various methods that employ heating to sterilize the container2are preferred. In one embodiment, the hot-brewed coffee beverage4may be flash pasteurized by heating it under pressure to a treatment or cure temperature of about 250° F. and then filling142and sealing144the container2. In another embodiment, following extraction of the hot-brewed coffee beverage4filling is performed followed by sealing the container144. Treating146of the packaged hot-brewed coffee beverages1is then performed by heating them under pressure, such as by use of a pressure cooker, to a treatment or cure temperature of about 250° F. and a pressure above ambient pressure to provide the aseptic, packaged hot-brewed coffee beverages1.