Method and system for the continuous or semi-continuous production of flavored ice

An ice making system includes a flavored liquid, an ice machine and a refrigerated storage bin. The ice making system continuously produces flavored ice pieces for storage in an ice storage bin. A refrigeration system cools the ice storage bin.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

The present disclosure relates to an ice making system for the continuous or semi-continuous production of flavored ice used in producing a flavored ice beverage (e.g., iced coffee). More specifically, the present disclosure relates to the formation of nugget ice by the extrusion of flaked ice with a flavored liquid, such as a coffee concentrate, which provides for reduced dilution of the beverage.

2. Description of Related Art

Consumers today often prefer chilled beverages that are traditionally served hot, as a cold or iced beverage, such as coffee and tea. In particular, iced coffee has become an extremely popular beverage. Typically, there are two ways to prepare an iced coffee beverage. First, is to brew a pot of hot coffee and then add regular ice cubes to chill. However, as the ice cubes melt over time the coffee becomes watered down or diluted, thus affecting the taste and quality of the beverage. A second way is to brew a pot of hot coffee and then place it in a refrigerator to chill. Unfortunately, this can take a while to chill and the coffee may become stale after an extended period of time. Thus, this can also have a negative effect on the taste and quality of the beverage.

Different methods have been developed in an attempt to overcome these disadvantages. One method is to double brew the coffee. Double-brewing involves doubling the amount of coffee grounds used to brew, thus providing a stronger flavored coffee. Therefore, as the ice melts and waters down or dilutes the coffee, a regular or average flavor of coffee is eventually achieved. This concept attempts to maintain the flavor as the ice melts and waters down the coffee. However, because the amount of ice used can vary, this often results in inconsistent flavor amongst the same product sold to customers. Since most producers of iced coffee seek to have a consistent flavor from drink to drink and from store to store, such inconsistent flavor is commercially unacceptable.

Another method used is to make coffee flavored ice or coffee ice cubes. This can be done using the same method and apparatus to make clear or batch style ice. In use, commercial and industrial ice making machines require a continuous circulation of an excess amount of water on the ice-making surface to provide the formation of clear ice. Thereafter, it is necessary to flush or dump a portion of the surplus water that contains the remaining concentrated minerals and chemicals to avoid freezing it into the ice. This process of making coffee ice cube requires a large amount of water, thus, increasing cost of production. Furthermore, it creates a considerable amount of foam and trapped air, resulting in ice having an undesirable hardness and consistency. Finally, it also results in a large quantity of coffee extract from being removed from the eventual ice cubes, thus creating a diluted and inconsistent iced coffee beverage.

Thus, there is a need for a method and an ice making system that continuously produces coffee ice without substantially diluting the resulting flavored beverage and/or without production of excess waste water or foam.

SUMMARY

The present disclosure provides for an ice making system including a flavored liquid or concentrate, an ice making machine and a storage bin for the continuous production of flavored ice pieces.

In one embodiment, the ice making system utilizes water and flavoring, such as coffee concentrate or coffee extract, which are mixed to produce the flavored liquid. In another embodiment, brewed coffee is directly used as the flavored liquid.

It is preferred that the ice making machine produces flavored ice nuggets. The ice making system may further include a reservoir to maintain the level of flavored liquid entering the nugget ice machine.

The storage bin of the present disclosure may be refrigerated for maintaining the flavored nugget ice quality and to prevent leaching of flavor from the flavored ice nugget.

In one embodiment of the system according to the present disclosure, an ice making system for making flavored ice pieces comprises a reservoir that holds a flavored liquid, an ice machine and a storage bin that stores the flavored ice pieces. The ice machine comprises an ice making evaporator and an augur centrally disposed within the evaporator. The ice machine receives the flavored liquid from the reservoir and produces the flavored ice pieces, which are then stored in the storage bin.

In another embodiment of the system according to the present disclosure, the ice pieces are selected from the group consisting of: flakes and nuggets.

In another embodiment of the system according to the present disclosure, the flavoring is selected from the group consisting of: a concentrate, extract, syrup, juice and other flavored product.

In another embodiment of the system according to the present disclosure, the flavoring is coffee, a coffee concentrate or a coffee extract.

In another embodiment of the system according to the present disclosure, a vessel stores a flavoring and a mixing device mixes the flavoring with water to produce the flavored liquid.

In another embodiment of the system according to the present disclosure, the mixing device comprises a mixing valve.

In another embodiment of the system according to the present disclosure, a pump controls a flow of the flavored liquid to the reservoir.

In another embodiment of the system according to the present disclosure, at least one refrigeration system refrigerates one or more selected from the group consisting of: the reservoir, the ice machine, the storage bin, the vessel, the mixing device, and the pump.

In another embodiment of the system according to the present disclosure, a control system controls the ice making machine to produce the flavored ice pieces.

In another embodiment of the system according to the present disclosure, a float mechanism is disposed to maintain a predetermined level of the flavored liquid in the reservoir. The control system deactivates the ice making machine if the flavored liquid drops below the predetermined level.

In another embodiment of the system according to the present disclosure, a temperature device is disposed in the storage bin. The control system regulates a temperature in the storage bin based on an output of the temperature measuring device.

In another embodiment of the system according to the present disclosure, the flavored ice pieces are removed from the storage bin either manually or automatically via a dispenser.

In one embodiment of the method according to the present disclosure, the method comprises holding a flavored liquid in a reservoir; delivering the flavored liquid from the reservoir to an ice making machine; producing the flavored ice pieces with the ice making machine; and storing the flavored ice pieces in a storage bin.

In another embodiment of the method according to the present disclosure, the ice pieces are selected from the group consisting of: flakes and nuggets.

In another embodiment of the method according to the present disclosure, the flavoring is selected from the group consisting of: a concentrate, extract, syrup, juice and other flavored product.

In another embodiment of the method according to the present disclosure, the flavoring is coffee, a coffee concentrate or a coffee extract.

In another embodiment of the method according to the present disclosure, the method further comprises storing a flavoring in a vessel and mixing the flavoring with water with a mixing device to produce the flavored liquid.

In another embodiment of the method according to the present disclosure, the method further comprises controlling with a pump a flow of the flavored liquid to the reservoir.

In another embodiment of the method according to the present disclosure, the method further comprises refrigerating one or more selected from the group consisting of: the reservoir, the ice machine, the storage bin, the vessel, the mixing device, and the pump.

In another embodiment of the method according to the present disclosure, the method further comprises maintaining a predetermined level of the flavored liquid in the reservoir and deactivating the ice making machine if the flavored liquid drops below the predetermined level.

In another embodiment of the method according to the present disclosure, the method further comprises regulating a temperature in the storage bin.

In another embodiment of the method according to the present disclosure, the method comprises removing the flavored ice pieces from the storage bin either manually or automatically.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring toFIG. 1, an ice making system10according to a first embodiment of the present disclosure comprises a flavored liquid, an ice machine14and a storage bin16. Ice making system10employs a different ice making process than batch style ice making, thus making an improved quality flavored ice.

In one embodiment, as shown inFIG. 1, the operation of ice making system10begins with water being provided from any water supply18, such as a water tap, water tank, distilled water, filtered water or other potable water supply. Water may be transported via tubes, pipes or other similar conduits19to a mixing valve20. Water entering ice making system10may pass through a water filtration type system.

In addition to water, mixing valve20receives a supply of a flavoring22via a conduit21. Flavoring22may be stored in a vessel23. Flavoring22can be any type of flavoring selected by the user, including, but not limited to, a flavored concentrate, extract, syrup, juice concentrate, or other flavored product. Preferably, flavoring22is a coffee concentrate or coffee extract.

Vessel23containing flavoring22may be housed in a compartment24that is insulated and refrigerated by a refrigeration system260to maintain flavoring22at a desired temperature, as shown inFIG. 1. Furthermore, vessel23is typically a bag or box container holding a known volume of flavoring22.

Preferably, mixing of water and flavoring22occurs in mixing valve20to produce a flavored liquid. Thereafter, the flavored liquid is metered via a pump26, e.g., a positive displacement pump, which controls the flow of flavored liquid to a reservoir28via a conduit12. This process generates a homogeneous solution of flavored liquid. In one embodiment, refrigeration system260also refrigerates mixing valve20and pump26.

Ice making system10also comprises a main control system250for the regulation of making flavored ice pieces. Main control system250is in communication with various elements, such as, pump26, reservoir28, ice machine14and storage bin16.

Optionally, mixing valve20is capable of detecting when vessel23no longer contains any flavoring22. Thus, ice making system10can provide the user with a warning or signal when flavoring22is empty and needs to be replaced. This warning or signal can be any type of signal, including, but not limited to, a visual or audio type signal.

Flavored liquid is transported from reservoir28via conduit13to ice machine14, as shown inFIG. 1. Ice machine14can be any type of ice machine, including, but not limited to, a nugget ice maker, a flaker ice maker or other similar ice machine. Preferably, ice machine14is an ice maker50for making nuggets, as shown inFIG. 2.

As shown inFIGS. 2 and 3, ice maker50may be a conventional augur-type ice machine that can transform the flavored liquid into flavored ice pieces or flakes, and thereafter into nuggets. It is preferred that ice maker50is a cylindrical augur-type ice machine having an ice making evaporator51. Evaporator51includes a heat exchange tube52carrying a refrigerant that is utilized for cooling an ice making chamber54. More specifically, heat exchange tube52extends into ice maker50near a lower portion of ice making chamber54, coils around a housing defining ice making chamber54, and exits the ice maker50near an upper portion of the ice making chamber54. The coiled portion of heat exchange tube52is surrounded by a casing56for insulative and protective purposes. Casing56is preferably made of metal, such as a tin-based solder. Alternately to this construction, seeFIG. 13wherein heat exchange may be accomplished using an annular space300formed by two concentric cylinders301and302, sometimes refer to as shell in shell.

Flavored liquid is delivered from reservoir28via a conduit13to a lower portion of ice making chamber54via an inlet port or supply tube58. Flavored liquid is preferably delivered to ice making chamber54via natural flow forces (for example, gravity). Flavored liquid typically fills ice making chamber54to the same level as reservoir28.

An augur60is positioned within ice making chamber54and includes a generally spiral-shaped augur flight62. Augur flight62has a diameter that is slightly less than the diameter of ice making chamber54so that augur flight62removes most of the ice build-up from the wall of ice making chamber54. For example, augur flight62has a diameter that is preferably between 0.001 and 0.01 inches smaller than the diameter of ice making chamber54so that all but a thin layer of ice is removed from the wall of ice making chamber54when augur60rotates. An augur motor (not shown) rotates augur60, in a direction so that augur flight62generates a lifting motion. As provided above, ice making chamber54is generally filled with flavored liquid along the length of augur60so that the flavored liquid adjacent to ice making chamber54wall is frozen into flavored ice crystals. Therefore, as the flavored ice crystals are being formed, the rotating augur flight62scrapes the layer of ice from the inner surface and transports the newly-formed flavored ice in an upward direction.

As shown inFIG. 3, the flavored ice is separated into pieces by an ice cutting head64having a plurality of generally vertical blades66. The leading edge of each of the blades66preferably has a tapered portion68to act as a wedge and split the ice into flavored ice pieces. Ice cutting head64is coupled to augur60so that ice cutting head64does not rotate along with augur flight62. Based on the size and shape of cutting head64, ice maker50can be used to form flavored ice pieces into a desired shape and size.

To form flavored ice nuggets, flavored ice pieces are then forced upwards past ice cutting head64and through an output end or opening70defined by ice making chamber54and ice cutting head64, where a rotating ice wiper72sweeps the flavored ice pieces away from opening70, as shown inFIG. 2. Ice wiper72, which includes a pair of projections74coupled to a body portion76, is connected to augur60such that the respective components60and72rotate in unison with each other. Body portion76has an arcuate, tapered underside surface that gradually urges the flavored ice pieces in a radial direction out of opening70. The ice that is extruded through the cutting head64breaks into one of the flavored ice nuggets upon contact with the underside of body portion76. Therefore, the distance between the tapered underside of body portion76and opening70controls the length of the flavored ice nuggets. Furthermore, as augur60and ice wiper72rotate, projections74sweep the flavored ice nuggets further away from opening70.

In addition, to alter the shape and the size of the flavored ice nuggets described, post-formation treatments squeeze out water clinging to the ice, thereby causing the flavored ice nuggets to have a higher cooling capacity per pound of ice and increasing the cooling potential of the flavored ice nuggets.

After being expelled from the ice making chamber54, the flavored ice nuggets move through a transfer zone and into storage bin16. The transfer zone is defined by a path between the ice making chamber54and storage bin16. For example, the transfer zone inFIG. 2includes, but is not limited to, the area adjacent to the ice making chamber opening70, a strainer78and an ice chute80. See US Patent Publication No. 2006/0277937 for an ice maker, which is incorporated herein in its entirety by reference thereto.

Reservoir28maintains the level of the flavored liquid being supplied to ice machine14via a mechanism30. Reservoir28may include a first mechanism for controlling the flavored liquid level in reservoir28, and a second mechanism for deactivating the ice machine14if the flavored liquid level is below a predetermined threshold. For example, as shown inFIGS. 4-6, reservoir28includes a float valve100configured to control a volume flow of flavored liquid into reservoir28and a level sensor102configured to detect a flavored liquid level within reservoir28.

Float valve100is a mechanically-actuated having a floating element104, a valve106, and an attachment arm108extending therebetween. When floating element104is positioned at or above a predetermined height within reservoir28, arm108causes valve106to be in a closed position (as shown by the floating element104drawn in the phantom line inFIG. 5). If floating element104moves below the predetermined height, arm108causes valve106to move into an open position, thereby permitting flavored liquid to flow into reservoir28.

Level sensor102is electrically connected to control system250to deactivate ice machine14if the flavored liquid in reservoir28drops below a predetermined level. Level sensor102includes a floating element110having a magnet coupled thereto and a guide arm112connecting floating element110to a reed switch114. Reed switch114detects the position of the magnet on floating element110to determine a threshold water level within reservoir28. Level sensor102is configured to activate an electrical circuit indicating to the control system that the flavored liquid level has dropped below a predetermined level (as shown by the floating element110drawn in the solid line inFIG. 5). However, if the flavored liquid is above the predetermined level (as shown by the floating element110drawn in the phantom line inFIG. 5), then level sensor102will deactivate the electrical circuit.

If the flavored liquid level in reservoir28is undesirably low, or if reservoir28is empty, ice making chamber54may not receive a sufficient amount of flavored liquid to make flavored ice. Additionally, the lack of flavored water in ice making chamber54may cause the chamber temperature to drop to an undesirable level; thereby causing damage to ice machine14. For example, if no flavored liquid is present in the ice making chamber54, the temperature therein will become too cold and the walls of ice making chamber54may be permanently deformed; thereby preventing an effective scraping contact between augur60and the walls of ice making chamber54and potentially damaging augur60.

As shown inFIG. 6, reservoir28also includes an overflow tube116that diverts flavored liquid if reservoir28is overflowing. More particularly, overflow tube116includes a stand-up portion116athat extends into the reservoir28by a predetermined distance. The predetermined distance is preferably greater than the normal operational flavored liquid level in reservoir28, such that when float valve100is functioning properly the flavored liquid level is below the top of stand-up portion116aof overflow tube116.

Furthermore, reservoir28includes a drainage tube118for draining flavored liquid from water reservoir28when desired. For example, when performing maintenance on and cleaning of ice making system10, it may be desirable to drain the flavored liquid from the system. During normal operation of ice making system10, a solenoid valve119closes drainage tube118to maintain the desired flavored liquid level within reservoir28, as shown in FIGS.1and7-9.

As shown inFIG. 1, flavored ice is then transported via a conduit15to storage bin16, where flavored ice nuggets32are stored until needed for consumption. Preferably, storage bin16is located below the top of ice machine40so flavored ice nugget32can naturally fall through or slide along the transfer zone into storage bin16via gravity. For this embodiment, conduit15may be an ice chute. However, it is also contemplated that flavored ice nuggets32can be transported in any direction via conduit15by pressure or pumps or other mechanisms.

Storage bin16has a storage area for holding flavored ice nugget32. Preferably, storage bin16comprises insulated exterior walls and a closable opening that provides a user with access to flavored ice nugget32. Furthermore, it is preferred that storage bin16is refrigerated by a mechanical refrigeration system262. Refrigeration system262may include a temperature measuring device and a control system to regulate the temperature. For example, the temperature measuring device includes a sensor that outputs a signal indicative of a current temperature in storage bin16. Control system250operates refrigeration system262to increase or decrease the current temperature to a desired or predetermined temperature.

Storage bin16maintains a temperature to stabilize flavored ice nugget32and prevent melting. In addition, stabilizing the temperature of storage bin16reduces leaching of flavoring22from flavored ice nugget32. Preferably the temperature in storage bin16is up to 32° F. More preferably, the temperature is between the range of about 20° F. and about 32° F.

In addition, storage bin16may include an electrical or mechanical device for determining the level of flavored ice nugget32within the storage area, such as a level sensor, an optical sensor, a reed switch or other similar electrical or mechanical device. This device may be in communication with ice machine14, pump26and/or mechanism30of reservoir28so as to regulate the flow of flavored liquid into ice machine14. Thus, the level of flavored ice nuggets32within storage bin16controls the operation of ice making system10. For example, as the level of flavored ice nugget32in storage bin16decreases to a set minimum level, ice machine system10begins production of flavored ice nugget32. Also, should the level of flavored ice nugget32reach a set maximum level, ice making system10will stop the production of flavored ice.

FIG. 7shows another embodiment of ice making system10of the present disclosure. In this embodiment, valve20and pump26are housed within refrigerated compartment24and thus stored in a refrigerated environment. This provides a more compact design and maintains the shelf life of flavoring22.

In yet another embodiment, as shown inFIG. 8, water18and flavoring22are not mixed within ice making system10to make flavored liquid. Instead, ice making system10has a pre-made flavored liquid disposed in container34provided by the user. Thus, flavored liquid within container34is supplied to ice machine14, preferably via reservoir28. For example, container34holds pre-made flavored liquid, such as brewed coffee, tea, juice etc. Preferably, container34holds brewed coffee.

FIG. 9shows another embodiment of ice making system10, having a receptacle36for holding water received from water supply18. Receptacle36may have a control38, such as a float valve, a dual level switch, etc., to detect the level of water within. Having receptacle36allows ice making system10to be portable since not restricted to being connected to a continuous water supply.

Furthermore, ice making system10may also have an automated maintenance feature for cleaning, sanitizing and flushing all residue and other elements from ice making system10. The maintenance system cleans valves, tubes, pumps, mixing chambers and reservoirs present in ice making system10. This may include an auxiliary fluid delivery system that distributes a liquid comprising a controlled ratio of cleaning solution and water or water itself.

As shown inFIG. 10, ice making system10is preferably housed within a housing200. Housing200has an upper or first compartment202and a lower or second compartment204, each having an insulated door206for opening and closing their respective compartments. It is preferred that upper compartment202and lower compartment204are refrigerated, thus each having an evaporator, compressor and condenser system as shown by refrigeration systems260and262inFIG. 1. However, it is also contemplated that housing200has a single evaporator, compressor and condenser system which provides refrigeration to each compartment. In addition the compressor(s) and/or condenser(s) may be remote from housing200to avoid noise and heat around the vicinity of housing200. Housing200can be made out of any durable material, such as, stainless steel, aluminum, plastic, etc.

As shown inFIG. 11, lower compartment204may include a number of components of ice making system10, including, but not limited to, receptacle36containing water, vessel23containing flavoring22, mixing valve20and pump26. Lower compartment204also provides the user with additional refrigerated storage space.

FIG. 12shows upper compartment202which may include reservoir28, ice machine14and storage bin16containing the continuously produced flavored ice nugget32. In some embodiments, reservoir28and ice machine14are not refrigerated, however, they are still within upper compartment202. Flavored ice nuggets32are accessible by a user in a variety of ways, including, but not limited to, being removed manually by a scoop or automatically using a dispenser. Upper compartment202further has delivery tubing that is in fluid communication with the components of lower compartment204. Upper compartment202may provide the user with additional refrigerated storage space.

The present disclosure having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the present disclosure as defined in the appended claims.