Patent Publication Number: US-2019183132-A1

Title: Apparatus, System and Method of Manufacturing Edible, Biodegradable Containers

Description:
FOREIGN PRIORITY CLAIM 
     This application claims the benefit of Bulgarian Patent Application No. 3934 (Issued Bulgarian Patent No. BG2894U1) entitled “Production Line for Edible, Biodegradable Containers for Hot and Cold Beverages and Food” invented by Miroslav Atanasov Zapryanov which was filed on Dec. 18, 2017 and published in Bulgarian Patent Bulletin No. 3.1 on Mar. 15, 2018. An English-language translation of such Bulgarian Patent is being concurrently filed herewith and is hereby incorporated by reference in this application. 
     BACKGROUND OF THE INVENTION 
     There is a known composition for producing edible, biodegradable containers for hot and cold beverages and food. Edible, biodegradable containers for hot and cold beverages are made from a composition, which contains, in certain weight percentages, the following ingredients: oat bran, flour, sugar, gluten, margarine, alginate, stabilizer, salt, potassium sorbate, flavoring and water. The containers with the proposed composition last a long time without decomposing and disintegrating even when used to store hot drinks. An example of such known composition is disclosed in Bulgarian Patent Application No. 3057 (Issued Bulgarian Patent No. BG2170U1) entitled “Ingredients for the Production of an Edible Cup for Cold and Hot Beverages” invented by Miroslav Atanasov Zapryanov which was filed on Jul. 27, 2015 and published in Bulgarian Patent Bulletin No. 1 on Jan. 29, 2016. 
     The edible, biodegradable containers for hot and cold beverages and food are handmade with a very low degree of automation. The manual production of these containers, which includes a number of operations such as kneading, molding and baking, etc., is a difficult and prolonged process with low productivity. 
     There is no known apparatus, system or method for the production of edible, biodegradable hot and cold beverages and food containers to automate the process and increase productivity to meet market needs. 
     SUMMARY OF THE INVENTION 
     The instant application is directed towards to an apparatus, system and method of manufacturing edible, biodegradable containers for hot and cold beverages and food. 
     The instant application discloses:
         (i) an apparatus for manufacturing edible, biodegradable containers for hot and cold beverages and food;   (ii) a system for manufacturing edible, biodegradable containers for hot and cold beverages and food; and   (iii) a method of manufacturing edible, biodegradable containers for hot and cold beverages and food;
 
which increases labor productivity and automates the manufacturing process.
       

     This objective is accomplished by an apparatus, system and method of manufacturing edible, biodegradable containers for hot and cold beverages and food, which consists of a control unit connected to a sequentially installed kneading machine, dosing machine, forming and baking machine, cooling tunnel, labeling machine and packaging machine, all of which are connected by a conveyor belt. 
     The forming and baking machine is comprised of at least one forming unit, which includes one or more forming sockets. Each forming socket consists of a body in which: (i) in certain embodiments, a demountable mold; or (ii) in certain embodiments, a non-removable mold; is affixed. In certain embodiments, such mold has a heater while in certain other embodiments, such mold does not have a heater (i.e., where there is gas heating). A punch is movably positioned in the mold, whereby a gap with a preselected width is formed between the mold and the punch. In embodiments utilizing electrical heating, a heater is installed in the punch cavity. In embodiments utilizing gas heating, a cavity is not needed. 
     The punch ends with a flange located outside of the forming socket, with openings predrilled on the periphery of the flange. Around the punch, beneath the flange, an unloading element having the shape of a washer is movably positioned, with openings predrilled at its periphery, coinciding with the openings on the flange. Linear guides are mounted in the peripheral openings of the flange and the unloading element. In the case where the body  11  is made of two or more parts this unloading element  15  is not necessary. 
     In one embodiment, the mold is in the form of a concave inverted cone whose outer surface forms the outer surface of the edible container. In one embodiment, such a mold could be further provided with vertical air and water vapor discharge grooves. 
     In one embodiment the punch is also in the form of an inverted truncated cone. In one embodiment, the punch also has on its sides longitudinal air and water discharge grooves formed in the mold-forming process of the containers. On the outer surface of the punch, there are cylindrical retaining grooves, perpendicular to the longitudinal grooves. 
     According to one embodiment, vertical grooves are provided on the inner surface of the unloading element, and radial grooves connected to the vertical ones are made on its upper plane. 
     According to another embodiment, the forming unit is constituted by a multitude of forming sockets, which are grouped in a common unit, the flanges of the punches being joined together in a common upper plate and the unloading elements in a common movable unloading plate, in which case the system is provided with locking mechanism. 
     One advantage of the instant invention is that the process of manufacturing edible, biodegradable containers is automated, which increases productivity and reduces the cost per unit of production. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a block diagram of the system for manufacturing edible, biodegradable containers for hot and cold beverages and food. 
         FIG. 2  is an axonometric view of a forming unit. 
         FIG. 3  is a first axonometric view of a forming socket. 
         FIG. 4  is a second axonometric view of a forming socket. 
         FIG. 5  is an axonometric view of a punch. 
         FIG. 6  is an axonometric view of the unloading element, which removes the finished container. 
     
    
    
     REFERENCE NUMERALS 
     
         
         
           
               1 . Kneading Machine 
               2 . Dosing Machine 
               3 . Forming and Baking Machine 
               4 . Cooling Tunnel 
               5 . Labeling Machine 
               6 . Packaging Machine 
               7 . Conveyor Belts 
               8 . Control Unit 
               9 . Forming Unit 
               10 . Forming Socket 
               11 . Body 
               12 . Demountable Mold 
               13 . Upper shape-forming body (punch) 
               14 . Flange 
               15 . Unloading Element 
               16 . Heater 
               17 . Fine Grooves 
               18 . Outer Surface Longitudinal Grooves 
               19 . Concentric Cylindrical Retaining Grooves 
               20 . Vertical Grooves 
               21 . Radial Grooves 
               22 . Carrier Plate 
               23 . Upper Plate 
               24 . Movable Unloading Plate 
               25 . Locking Mechanism 
               26 . Cylindrical Openings 
               27 . Cylindrical Openings 
           
         
       
    
     DETAILED DESCRIPTION OF THE INVENTION 
     An example of the embodiment of an apparatus, system and method of manufacturing edible, biodegradable containers for hot and cold beverages and food is shown in  FIG. 1 . This apparatus, system and method of manufacturing edible, biodegradable containers is, in particular, adapted for the production of containers for coffee. 
     The system of manufacturing edible, biodegradable containers for hot and cold beverages and food consists of sequentially installed kneading machine  1 , a dosing machine  2 , a forming and baking machine  3 , a cooling tunnel  4 , a labeling machine  5  and a packaging machine  6 . Conveyor belts  7  are installed between the individual units of the system to transport the produce. The composite parts of the system are also connected to a control unit  8 , by means of which adjustment, coordination and automation of the production processes are achieved. 
     The main and most important unit of the system is the forming and baking machine  3 , i.e., the apparatus for manufacturing edible, biodegradable containers for hot and cold beverages and food, which consists of at least one forming unit  9  as shown in  FIG. 2 . In turn, each forming unit  9  is constituted by at least one forming socket  10  as shown in  FIG. 3  and  FIG. 4 . 
     The forming sockets  10  may be of any shape. For example, the forming sockets  10  may imitate a coffee cup, tea cup, soup bowl, etc. In the embodiment shown in the drawings, an example of a coffee cup forming socket  10  is given. 
     In the embodiment shown in the drawings, each forming socket  10  is formed by a body  11  in which a demountable mold  12  is affixed. Alternatively, as not pictured in the drawings, the mold  12  could be non-removable and carved directly in the body  11 . The body  11  can be made up of one, two, or more than two opening parts. An upper shape-forming body (i.e., a “punch”)  13  is movably positioned in the demountable mold  12 . 
     The punch  13  ends with a flange  14  whose periphery has cylindrical openings  26 . Around the punch  13 , beneath the flange  14 , an unloading element  15  having the shape of a washer is movably positioned, with openings  27  predrilled at its periphery. The unloading element  15  is used to remove the already baked container from the punch  13 . In the case where the body  11  is made of two or more parts, this unloading element  15  is not necessary. 
     In the cylindrical openings  26  of the flange  14  and in the cylindrical openings  27  of the unloading element  15  are mounted linear guides (not shown in the figures) which provide the linear movement of the unloading element  15  relative to the punch  13 . 
     On the inner surface of the unloading element  15  there are fine longitudinal grooves as in  FIG. 6 . 
     In the central portion of the punch  13 , along its inner cavity, at least one heater  16  is provided for the baking of the edible container (e.g., a coffee cup) as shown in  FIG. 4  and  FIG. 5  in the electrical heating embodiment shown in drawings. In embodiments having gas heating (not shown in the drawings), a cavity is not necessary. 
     As noted above, the mold  12  (which is shown in the drawings as having the shape of an inverted truncated cone) is mounted in the body  11 . The mold  12  forms the outer surface of the edible container. In certain embodiments, the mold  12  can be provided with fine grooves  17 , most often vertical along the inner surface of the mold  12 . In other embodiments (not shown in the drawings), the mold  12  can be provided without fine grooves  17 . The grooves  17  serve to remove air and water vapor that are produced during the forming and baking process of the container. In the body  11 , heaters are mounted near the mold  12  for the baking of the edible container in certain embodiments. These heaters are not shown in the attached figures. In other embodiments (e.g., in the case of gas heating), there are no such heaters. 
     In certain embodiments, the punch  13  is also in the form of an inverted truncated cone, having on its outer surface longitudinal grooves  18 , which function to discharge the air and water produced in the container forming process. In other embodiments, the punch  13  does not have such longitudinal grooves  18 . On the outer surface of the punch  13 , there are also concentric cylindrical retaining grooves  19 , perpendicular to the longitudinal grooves  18 . The retaining grooves  19  ensure that the finished container (e.g., the ready coffee cup) remains fixed to the punch  13 . In the case where the body  11  is made of two or more opening parts and there is no unloading element  15 , such retaining grooves  19  are not necessary. 
     On the inner surface of the unloading element  15 , vertical grooves  20  are provided for the discharge of air and water vapor formed in the container forming process. On the upper plane of the unloading element  15 , radial grooves  21  are provided which are connected to the vertical ones  20 . 
     In one embodiment, each forming unit  9  may have a plurality of forming sockets  10  of different number, type and shape, which when actuated form separate containers of the same or different shape depending on the forming sockets used as shown in  FIG. 2 . 
     In certain embodiments, several forming sockets  10  are joined together in a common forming unit  9  then the bodies  11  may be separated from one another while being grouped together in a common carrier plate  22 . This also means that the cylindrical parts of the sockets  10  (i.e., the flanges  14  of the punches  13 ) are joined together in a common upper plate  23 , and the unloading elements  15  are joined in a common movable unloading plate  24 . In such embodiments where the carrier plate  22  is made of two or more parts, the unloading plate  24  is not necessary. 
     In this case, the system is provided with a locking mechanism  25  which functions to ensure that the upper plate  23  remains stationary relative to the carrier plate  22  during the baking process. In the embodiment shown in the drawings, such locking mechanism  25  is shown as a “clamp,” but the locking mechanism  25  could consist of any similar means for locking known in the art (and the selection of such mechanism could depend on the number of sockets  10 ). 
     All elements of the forming and baking machine  3  are made of metal suitable for food contact—for example, aluminum, stainless steel, cast iron or others, which possess the required qualities. 
     The method of manufacturing the containers consists of the following steps in sequence:
         1. mixing of the ingredients necessary for the production of the edible containers to create a dough;   2. kneading said dough;   3. dosing said dough (i.e., apportioning the proper amount of dough);   4. forming and baking of the edible containers;   5. cooling of the products;   6. (optionally) labeling; and   7. (optionally) packaging the finished containers.       

     An example of the composition for the production of edible, biodegradable hot and cold beverage and food containers includes (by percent weight): oat bran—24%; flour—20.5%; sugar—8.2%; gluten—5.7%; margarine—8.2%; alginate—0.82%; xanthan gum—0.82%; salt—0.41%; potassium sorbate—0.82%; flavoring—1.23%—with the remainder consisting of water. 
     The weighing and portioning of the individual components may be accomplished by using a balance and standardized containers designed and meeting the requirements of the food industry. After this, the dry products (e.g., flour, oat bran, dry gluten, sugar, salt and alginate) are weighed and then mixed. Next comes the addition of the water, margarine and flavoring. Then follows a process of mixing of the ingredients, which is carried out using the kneading machine  1  (e.g., a dough mixer) as shown in  FIG. 1 . 
     After kneading and resting, the dough, via the conveyor belt  7 , is fed to a collecting hopper of a dosing machine  2  (shown in  FIG. 1  but not shown in the accompanying figures). The dough is divided into precise doses, each with a weight corresponding to the weight of the container to be manufactured (e.g., containers for coffee). 
     The dough already dosed is placed in the sockets of the forming and baking machine  3 . In certain embodiments, the forming and baking machine  3  can be provided with a hydraulic or pneumatic press (not shown in the figures). The forming and baking machine  3  also has the necessary sockets  10  in which the containers are formed. The forming unit  9  itself may contain sockets  10  of a different number, type and shape, thus forming the individual containers. 
     Then each dose of dough is molded by pressing each pre-heated punch  13  to its respective heated mold  12 . 
     The baking of the dough, after molding it between the two parts of the socket, is carried out at a baking temperature between 150° C. and 180° C. for a certain period. For this purpose, the mold  12  and the punch  13  are constantly heated, while temperature controllers are responsible to maintain the desired exact temperature. 
     The baking time is in direct dependency on the baking temperature, on the container size and thickness, and the desired degree of doneness. Normally, the baking time is approximately 2 to 2.5 minutes. 
     By closing the individual parts of the forming unit  9  by means of the locking mechanism  25  and starting to bake the dough, water starts to evaporate (i.e., the water in the dough is evaporated). This, in turn, leads to an increase in pressure inside the molds  12 . Pressure is desirable to achieve good homogeneity and density of the container, but pressure values greater than desired can lead to an explosion. In certain embodiments, excessive pressure is prevented by means of air and vapor grooves (for example as shown in  17 ,  18 ,  20  and  21 ) and openings, thus controlling the pressure value. In practice, the process for making the wafer containers (e.g., containers for coffee) may be thought of as “baking under pressure.” 
     As noted, the heating of the forming sockets  10  and the punches  13  is achieved by means of coiled heating elements, but can also be achieved in other ways, for example by gas or by preheated fluid circulating through the mold. 
     The unloading element  15 , or, respectively, the common unloading plate  24 , is designed to “push” the finished container(s) from the punch  13 . This happens as the movement of the unloading element  15 , or of the unloading plate  24 , respectively, is limited a few moments before the press stops its opening movement, after baking is complete. The unloading element  15  may also be in the form of separate rings, a separate element, or embedded in the punch. 
     In order to increase the range of input materials in the forming and baking machine  3 , a space for forming a molding flash may be provided in the mold  12 . This space is at the top of the mold  12  and is intended to provide smooth balancing of the pressure inside the mold  12 . Due to this balancing, it is possible for the excess material to exit smoothly. 
     The resulting container is then cooled to room temperature in the cooling tunnel  4  and is transported for labeling and packaging in the machines for labeling  5  and packaging  6 . 
     Optionally, a complementary element may be attached to the container thus obtained. For example, a label, which is an arc-shaped adhesive tape with a folding handle may be attached to the manufactured containers. 
     In an alternative embodiment, the container of this composition, for the convenience of the user, may be produced with a handle of the same dough. 
     The entire production process of the system is coordinated, adjusted and automated by the control unit  8 . 
     A container thus prepared is a slightly hygroscopic, edible wafer (biscuit) container, i.e., a cup or bowl. It is designed for serving hot and cold liquids such as soups, coffee, cappuccino, hot chocolate, hot and cold milk and other food and beverages. The container thus prepared can be consumed, for example, after drinking the beverage. 
     The container thus created, if disposed of in the environment, rather than being eaten, is ecologically safe and 100% biodegradable in a short time.