Abstract:
A method of decarbonating fermented liquids in-line may include directing a carbonated malt-based liquid through a nozzle, and directing the carbonated malt-based liquid from the nozzle into a space maintained at a partial vacuum pressure. The method may further include maintaining the carbonated malt-based beverage in the space until substantially all of the carbon dioxide dissolved within the carbonated malt-based beverage has been removed to provide a non-carbonated liquid, and removing the non-carbonated liquid from the space at substantially the same rate that the carbonated malt-based liquid is directed into the space.

Description:
TECHNICAL FIELD 
     In general, the present disclosure relates to personalized beverages. More specifically, the present disclosure relates to fermented beverages, such as malt-based beverages, that may be personalized to a consumer&#39;s preference, such as by combining ingredients together. 
     BACKGROUND 
     In recent years, malt-based beverages, and especially beers, are a fast growing market in many countries such as China and India. In many commercial establishments, these malt-based beverages are dispensed from large commercial dispensing taps. However, such systems are not logical for adaptation for wide personal use. Rather, personal servings of malt-based beverages are independently packaged for transport and sale. However, the preparation and transportation of personal malt or cereal based beverages has come at great expense. Due to their nature, malt or cereal based beverages have traditionally been carbonated at their source and then transported to their end destination in amber or otherwise dark colored glass bottles or aluminum cans. Dark colored glass bottles and aluminum cans have been the traditional containers for the storage and transportation of malt or cereal based beverages because they provide secure containment of the carbonated liquid without the release of unacceptable levels of carbon dioxide during storage. Additionally, dark colored bottles and aluminum cans are configured to prevent the exposure of the malt or cereal based beverage to the degrading effects of ultraviolet (UV) radiation from the sun or other light sources. 
     Traditional bottles and aluminum cans have also been designed to have generally cylindrical shapes due to the ease of manufacturing such shapes. However, the generally cylindrical shape of glass bottles and aluminum cans are inefficient for storage and transport. Cylindrical shapes are unable to be efficiently stacked for transport or storage without a large amount of wasted space between the cylindrical shapes. Furthermore, cylindrical shapes can typically only be stacked in a single vertical layer without becoming unstable for transportation. Consequently, square or rectangular structural containers and large amounts of packaging material are typically used for the transportation and stabilization of multiple cylindrical containers. 
     A need exists for a container that can be used for the efficient storage and transport of cereal or malt based personal beverages. 
     SUMMARY 
     In one aspect of the present disclosure, a method of decarbonating fermented liquids in-line may comprise directing a carbonated malt-based liquid through a nozzle, and directing the carbonated malt-based liquid from the nozzle into a space maintained at a partial vacuum pressure. The method may further comprise maintaining the carbonated malt-based beverage in the space until substantially all of the carbon dioxide dissolved within the carbonated malt-based beverage has been removed to provide a non-carbonated liquid, and removing the non-carbonated liquid from the space at substantially the same rate that the carbonated malt-based liquid is directed into the space. 
     In a further aspect, which may be combined with any other aspects, directing the carbonated malt-based liquid from the nozzle into the space may comprises distributing the carbonated malt-based over a surface. 
     In a further aspect, which may be combined with any other aspects, directing the carbonated malt-based liquid over the surface may comprise directing the carbonated malt-based liquid over a wall of a cylindrical vessel defining the space. 
     In a further aspect, which may be combined with any other aspects, the method may further comprise heating the carbonated malt-based liquid. 
     In a further aspect, which may be combined with any other aspects, heating the carbonated malt-based liquid may comprise heating the carbonated malt-based beverage to a temperature between about 35° C. and about 38° C. 
     In a further aspect, which may be combined with any other aspects, the space may be maintained at an absolute pressure of about 10 kPa. 
     In a further aspect, which may be combined with any other aspects, the carbonated malt-based liquid may comprise an ethyl alcohol content of at least 0.1% wt. 
     In a further aspect, which may be combined with any other aspects, the carbonated malt-based liquid may comprise an ethyl alcohol content of at least 0.5% wt. 
     In a further aspect, which may be combined with any other aspects, the carbonated malt-based liquid may comprise an ethyl alcohol content of at least 1% wt. 
     In a further aspect, which may be combined with any other aspects, the carbonated malt-based liquid may comprise an ethyl alcohol content between about 3% wt and about 12% wt. 
     In a further aspect, which may be combined with any other aspects, the carbonated malt-based beverage may comprise between about 3% wt malt extract solids and about 5.5% wt malt extract solids. 
     In a further aspect, which may be combined with any other aspects, the carbonated malt-based beverage may comprise less than about 6 International Bitterness Units. 
     In a further aspect, which may be combined with any other aspects, the carbonated malt-based beverage may comprise less than about 3 International Bitterness Units. 
     In a further aspect, which may be combined with any other aspects, the carbonated malt-based beverage may comprise about zero International Bitterness Units. 
     In a further aspect, which may be combined with any other aspects, the non-carbonated liquid removed from the space may comprise a carbon dioxide level between about zero grams per liter and about 1.5 grams per liter. 
     In one aspect of the present disclosure, a method of decarbonating fermented liquids in-line may comprise heating a carbonated malt-based liquid, directing a carbonated malt-based liquid through a nozzle, and distributing the carbonated malt-based liquid over a surface within a space with the nozzle. The method may further comprise maintaining the space at a partial vacuum pressure, maintaining the carbonated malt-based beverage in the space until substantially all of the carbon dioxide dissolved within the carbonated malt-based beverage has been removed to provide a non-carbonated liquid, and removing the non-carbonated liquid from the space at substantially the same rate that the carbonated malt-based liquid is directed into the space. 
     In a further aspect, which may be combined with any other aspects, heating the carbonated malt-based liquid may comprise heating the carbonated malt-based beverage to a temperature between about 35° C. and about 38° C. 
     In a further aspect, which may be combined with any other aspects, the non-carbonated liquid removed from the space may comprise a carbon dioxide level between about zero grams per liter and about 1.5 grams per liter. 
     In a further aspect, which may be combined with any other aspects, the carbonated malt-based liquid may comprise an ethyl alcohol content between about 3% wt and about 12% wt, and may comprise between about 3% wt malt extract solids and about 5.5% wt malt extract solids. 
     In a further aspect, which may be combined with any other aspects, the carbonated malt-based beverage may comprise less than about 6 International Bitterness Units. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings illustrate various embodiments of the present method and system and are a part of the specification. The illustrated embodiments are merely examples of the present system and method and do not limit the scope thereof. 
         FIG. 1  is a schematic process diagram depicting stages of the manufacture process for a base liquid for making a personalized malt-based beverage, according to an embodiment of the present disclosure. 
         FIG. 2  is a front perspective view of a non-rigid gusseted retort package containing a base liquid, according to one embodiment of the present disclosure. 
         FIGS. 3A and 3B  are perspective views of exemplary containers, according to various embodiments of the present disclosure. 
         FIG. 4  is an isometric view of a processing line for manufacturing non-rigid packages containing a base liquid, such as may be made by the process of  FIG. 1 . 
         FIG. 5  is a detail view of a non-rigid package manufactured, such as made on the processing line of  FIG. 4 . 
         FIG. 6  is a cross-sectional detail view of a sealing strip for use in non-rigid packages, such as shown in  FIG. 5 . 
         FIG. 7  is a side cross-sectional view of a shipping vehicle containing a number of non-rigid packages of decarbonated beer base efficiently stacked, according to an embodiment of the present disclosure. 
         FIG. 8  is a flow chart detailing a process for in-line decarbonation of fermented liquids, according to one exemplary embodiment. 
     
    
    
     Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements. 
     DETAILED DESCRIPTION 
     Embodiments described herein provide devices, systems and methods for the storage and transport of personal fermented beverages, such as fermented malt-based beverages. In the present disclosure, it should be understood that the present system will be described with reference to malt-based beverages. However, the present systems and methods equally apply to all cereal and pseudo-cereal based beverages, including, but in no way limited to beverages based on maize, rice, wheat, barley, sorghum, millet, oats, triticale, rye, buckwheat, fonio, and quinoa. In some embodiments, at least one base liquid may be manufactured that includes water and ethyl alcohol, and other ingredients derived from the brewing and fermentation of sugars, such as sugars extracted from malted grain, and may, according to various embodiments, include any number of flavors. The base liquid may be decarbonated after fermentation, to provide a still base liquid. The still base liquid, which may be substantially free of carbon dioxide or other dissolved gasses, may then be packaged, such as in a carton. The base liquid may then be shipped and sold to consumers, where it may be combined with carbon dioxide and otherwise prepared for consumption. 
     In some embodiments, a base liquid  10  for making a personalized fermented beverage may be manufactured by fermenting a wort  12  comprising fermentable sugars and water, as illustrated in  FIG. 1 . The fermentable sugars may be obtained by mashing a carbohydrate source  14  (i.e., utilizing enzymes to convert complex sugars to simple, fermentable sugars), such as malted barley and/or adjuncts such as one or more of maize, corn, rye, wheat, oat, rice, millet, sorghum, cassava root, potato, yam, agave, and persimmon. After mashing, liquid wort  12  may be separated from solids (e.g., grain husks) from the carbohydrate source by lautering. Optionally, fermentable sugars may be added to the wort  12  that do not require mashing, such as one or more of honey, cane sugar, beet sugar, molasses, fruit sugar (fructose), agave syrup, maple syrup, and corn sugar. 
     Various base liquids  10  may be prepared by utilizing different ingredients for preparing the wort  12 . Ingredients may be selected to provide a desired color, a desired ethyl alcohol content, and desired flavor profiles. For example, a roasted barley malt (e.g., black patent malt and/or chocolate malt) may be added to provide a dark base liquid  10 . For another example, adjuncts such as rice sugar, corn sugar, and/or cane sugar may be added to provide additional ethyl alcohol in a base liquid without adding significant flavor or color, such as for a light colored base liquid  10 . In yet another example, wheat may be added to provide a wheat base liquid  10 . 
     The wort  12  may then be boiled, and optionally, a small amount of bittering agents, such as hops or hops derivatives, may be added prior to or during the boiling process. In some embodiments, no bittering agents may be added. For example, the wort  12 , and the resulting base liquid  10 , may include less than about 6 International Bitterness Units (IBUs) (i.e., having less than about 6 milligrams of isomerized alpha acid per one liter of liquid). In another example, the wort  12 , and the resulting base liquid  10 , may include less than about 3 IBUs. In yet another example, the wort  12 , and the resulting base liquid  10 , may include about zero IBUs. 
     After boiling, the wort  12  may be cooled and yeast may be added to ferment the wort  12  (e.g., to convert the fermentable sugars in the wort  12  to ethyl alcohol and carbon dioxide). The yeast and fermentation process may be selected to affect the flavor of the resulting base liquid  10 . For example, a top fermenting yeast (i.e., an ale yeast) may be selected and fermenting temperatures may be relatively warm (e.g., between about 13° C. and about 24° C.) to provide a base liquid  10  having flavors of an ale style beer. For another example, a bottom fermenting yeast (i.e., a lager yeast) may be selected and fermenting temperatures may be relatively cool (e.g., between about 0° C. and about 13° C.) to provide a base liquid  10  having flavors of a lager style beer. In yet another example, a bottom fermenting yeast (i.e., a lager yeast) may be selected and fermenting temperatures may be relatively warm (e.g., between about 13° C. and about 24° C.) to provide a base liquid  10  having flavors of a steam style beer. 
     When the fermentation process has completed, a carbonated base liquid  16  may result that comprises an ethyl alcohol level of at least 0.1% wt and dissolved carbon dioxide produced by the yeast during fermentation. In some embodiments the base liquid  10  may comprise an ethyl alcohol level of at least 0.5% wt. In further embodiments, the base liquid  10  may comprise an ethyl alcohol level of at least 1% wt. For example, the base liquid  10  may comprise an ethyl alcohol level between about 3% wt and about 12% wt. 
     Bittering ingredients may, according to one exemplary embodiment, be included in the base liquid. Such bittering ingredients may include one or more of hops, dandelion, pine, spruce, nettle, scotch broom, heather, and other bittering ingredients. Likewise, aromatic ingredients may be used to flavor the base liquid. Such aromatic ingredients may include one or more of hops; citrus peel; coffee; tea; oak; charred wood; spices such as cinnamon, coriander, and curacao; fruits such as cherry, raspberry, peach, apple, and apricots; vegetables such as pumpkin, and blue agave nectar; and cereals such as malted barley, rye, wheat, rice, and millet. 
     Prior to packaging, the carbonated base liquid  16  may be decarbonated by known methods, or new methods, to remove substantially all of the dissolved carbon dioxide gas, and any other gases, to provide the base liquid  10 . For example, after decarbonation the base liquid  10  may have a carbon dioxide level between about zero grams per liter and about 1.5 grams per liter. According to one embodiment, after decarbonation, the base liquid  10  may have a carbon dioxide level between about zero grams per liter and about 1.0 grams per liter. According to yet another embodiment, after decarbonation, the base liquid  10  may have a carbon dioxide level between about zero grams per liter and about 0.6 grams per liter. Additionally, after fermentation, and prior to packaging, the base liquid  10  may be filtered to remove a portion of the solids. 
     Optionally, a carbonated liquid base  16  may be transported in bulk, such as by a tanker truck, from a brewery to a separate packaging plant. The carbonated base liquid  16  may then be decarbonated and packaged into individual containers, such as cartons, at the packaging plant to provide an individually packaged base liquid  18 . The generation of multiple decarbonated base liquids allows the consumer to select from a number of individually packaged base liquids  18  in varying levels of alcohol content, flavor, and bitterness level, to allow for consumer preferences. 
     In some embodiments, the carbonated base liquid  16  may be decarbonated inline prior to packaging, as illustrated in  FIG. 8 . The inline decarbonation may be conducted within a space, such as a cylindrical chamber, that may be subjected to a partial vacuum. Prior to being introduced into the space, the carbonated base liquid  16  may be heated (step  800 ), such as to a temperature between about 35° C. and about 38° C. The space may be maintained at a partial vacuum pressure, such as an absolute pressure of about 10 kPa. 
     The heated, carbonated base liquid  16  may be injected onto the space (step  810 ) via a nozzle, which may distribute the base liquid over a surface within the space, such as a wall defining the space. Alternatively, any number of specially shaped objects having any number of varying cross-sectional profiles may be included in the space to receive the heated, carbonated base liquid  16  as it is injected into the space to create sufficient agitation that the carbon dioxide is remove from the liquid. Within the space, the heat and vacuum conditions, along with the optional impact with a surface, may cause the carbon dioxide dissolved within the carbonated base liquid  16  to separate from the liquid and be withdrawn from the space. After the carbon dioxide has been substantially removed from the carbonated base liquid  16  to form the base liquid  10  (step  820 ), the base liquid  10  may settle at the bottom of the space and be withdrawn from the space to a filler apparatus (step  830 ), such as those known in the art, for packaging to provide the packaged base liquid  18 . 
     As the base liquid  18  is substantially free of carbonation (i.e., dissolved gases), the individual containers utilized for the packaged base liquid  18  may be non-rigid (e.g., soft-sided or flexible) containers, and the base liquid  18  may be hermetically sealed within an orifice defined by a non-rigid wall of the container. In some embodiments, a non-rigid container may be formed from a flexible sheet material, which may comprise one or more of paper pulp, a polymer, and/or a metal foil. For example, a non-rigid container may be comprised of a flexible sheet material comprising a multi-layer laminate having a first polyethylene layer, a paper layer, a second polyethylene layer, an aluminum foil layer, a polyethylene adhesion layer, and a third polyethylene layer. Accordingly, although a non-rigid container may be suitable for a liquid that is substantially free of any dissolved gases, non-rigid containers may not be suitable for carbonated liquids, as the flexible sides of a non-rigid container may not provide support for a pressure difference between the content therein and the ambient environment. The non-rigid containers  19 ,  20 ,  21  may be configured to hold between about 0.5 liter and about 10 liters. For example, the individual containers may be foil-on-foil, gusseted retort packages  19 , as shown in  FIG. 2 , having a gusseted base configured to facilitate a vertical orientation of the gusseted retort packages  19 . For another example, the individual containers may be an aseptic composite material carton  20 , such as the Tetra Gemina Aseptic® available from Tetra Pak Inc. of Vernon Hills, Ill., USA, as shown in  FIG. 3A . For a further example, the individual containers may be a carton  21  with a gusseted top, such as the Tetra Rex® available from Tetra Pak Inc. of Vernon Hills, Ill., USA, as shown in  FIG. 3B . Any number of flexible materials configured to hermetically store a liquid, including polymers, may be used to form the individual containers of the present exemplary system and method. 
     An example of a portion of a process for forming non-rigid containers  19 ,  20 ,  21  from sheet material is illustrated in  FIG. 4 . A flexible sheet material  23  may be provided, such as from a roll, the flexible sheet material  23  having a first edge  25  and an opposing second edge  27 . A sealing strip  29  may also be provided, such as from a roll. The sealing strip  29  may then be adhered to the first edge  25  of the flexible sheet material  23 , so that it extends over the first edge  25 . The flexible sheet material  23  with the sealing strip  29  adhered thereto may be sanitized in a chemical bath, such as a hydrogen peroxide bath  31 . 
     The flexible sheet material  23  may then be creased and folded with progressive roller units  33  to form a tube  35 . According to one exemplary embodiment, the tube  35  may have any number of cross-sectional shapes including, but in no way limited to, circular, oval, square, rectangular, or triangular cross-section. To form the tube  35 , the first and second edges  25  and  27  of the sheet material  23  may be positioned to overlap and be secured together with an adhesive. Additionally, the portion of the sealing strip  29  that overhangs the first edge  25  may be adhered to the sheet material  23  proximate to the second edge  27 , to provide a longitudinal or transverse seal along the seam within the interior of the tube  35  (and thus within the interior of the resulting non-rigid containers  19 ,  20 ,  21 ), as shown in  FIG. 5 . 
     Referring again to  FIG. 4 , the tube may then be filled with base liquid  10  via a delivery tube  37  prior to segments of the tube  35  being sealed to form package precursors  39 , which are then cut from the tube  35  to provide discrete non-rigid containers  19 ,  20 ,  21  of packaged base liquid  18 . 
     To maintain freshness of the packaged base liquid  18 , the sealing strip  29  that provides the longitudinal transverse seal of the non-rigid container  19 ,  20 ,  21  may include a material layer that provides an oxygen barrier. In some embodiments, the sealing strip  29  may comprise a layer of ethylene vinyl alcohol (EVOH). For example, as shown in  FIG. 6 , the sealing strip  29  may comprise a plurality of layers and may comprise a layer  41  of EVOH sandwiched between layers  43  of polyethylene terephthalate (PET). Alternatively, the sealing strip  29  may be formed of a laminate that includes any number of polymer layers, including, but in no way limited to nylon, to increase the hermetic seal of the resulting non-rigid container  19 ,  20 ,  21 . 
     The use of non-rigid containers  19 ,  20 ,  21  may facilitate cost effective shipping of the packaged base liquid  18 . Non-rigid containers  19 ,  20 ,  21  may be relatively light weight, may be configured to stack efficiently, reducing dead space between packages, and may be allow relatively rough handling. For example, the packages may be stacked in a geometrically efficient manner based on a flat-sided geometry, and such stacked packages may be efficiently shipped. According to one exemplary embodiment, packages having a square or rectangular cross-section may be stacked with adjacent flat sides touching, thereby eliminating unused volumes in transportation containers.  FIG. 7  illustrates a transportation truck  1300  having a number of non-rigid containers  19 ,  20 ,  21  having a rectangular cross-section, stacked in an efficient manner. As illustrated in  FIG. 7 , each non-rigid container  19 ,  20 ,  21 , with the exception of the edge containers, is stacked with a container immediately above, below, to the left, and to the right. This efficient stacking system, mating adjacent planar surfaces, allows for the shipment of the maximum volume of product. In contrast, traditional containers used for carbonated alcoholic beverages were cylindrically shaped, resulting in a high level of unused space when shipped. As further illustrated in  FIG. 7 , a number of structural stacking dividers  1310  are included between multiple layers of flexible containers  19 ,  20 ,  21  to ensure that the maximum compression levels of the flexible containers is not exceeded by the bottom container supporting all containers resting thereon. 
     Non-rigid containers  19 ,  20 ,  21  may also facilitate reliability and quality of the product received by an end consumer. Non-rigid containers  19 ,  20 ,  21  may facilitate the pasteurization, or ultra-pasteurization, of the packaged base liquid  18  after packaging. This may eliminate the possibility of the packaged base liquid  18  from being contaminated with microorganisms. Non-rigid containers  19 ,  20 ,  21  may additionally facilitate the inclusion of labels and information directly on the package, which may be aesthetically pleasing to an end consumer. Furthermore, non-rigid containers  19 ,  20 ,  21  may be environmentally friendly. Although there are many advantages to utilizing non-rigid containers  19 ,  20 ,  21 , rigid containers, such as bottles and cans comprised of one or more of plastic, glass, and metal, may also be utilized. 
     In some embodiments, the packaged base liquid  18  may have a composition comprising a water content between about 89% wt and about 94% wt, a malt extract solids (e.g., beer flavor) content between about 3% wt and about 5.5% wt, a carbon dioxide content less that about 0.15% wt, and an ethyl alcohol content between about 0.1% wt and about 8% wt. Alternatively, according to one exemplary embodiment, the packaged base liquid  18  may have an apparent extract between −1 Degree Plato to 8 Degree Plato, with at least 50% coming from cereal. Additionally, as previously discussed herein, the base liquid  10  or the packaged base liquid  18  may be pasteurized, or ultra-pasteurized, to deactivate or kill any remaining yeast and/or other microorganisms therein. 
     Once the base liquid  10  is delivered to the consumer, it may be carbonated via any number of methods known in the art including, but in no way limited to a streamed or forced dissolution of carbon dioxide, nitrogen, and/or other gases into the base liquid. The preceding description has been presented only to illustrate and describe exemplary embodiments of the invention. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined by the following claims.