US 201403701 81A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2014/0370181 A1 Young et al. (43) Pub. Date: Dec. 18, 2014
(54) COFFEE COMPOSITION FOR USE WITH A Publication Classification BEVERAGE UNIT AND METHODS OF USING THE SAME (51) Int. Cl. A23F5/04 (2006.01) (71) Applicant: The Folger Coffee Company, Orrville, A23F 5/38 (2006.01) OH (US) A23F5/08 (2006.01) (52) U.S. Cl. (72) Inventors: Jerry Douglas Young, Medina, OH CPC. A23F5/04 (2013.01); A23F5/08 (2013.01); (US); Robert David Piotrowski, A23F 5/38 (2013.01) Medina, OH (US); Donald Lee Hughes, USPC ...... 426/595; 426/466: 426/518; 426/507 Akron, OH (US) (57) ABSTRACT The present invention provides a coffee composition for use (73) Assignee: The Folger Coffee Company, Orrville, with a single serve beverage unit. The beverage unit consists OH (US) of a container having a first structure to enable the introduc tion of a liquid Such as hot water into the container to contact the coffee composition and a second structure to enable the (21) Appl. No.: 14/213,349 release of a coffee extract out of the container. The coffee composition comprises various coffee ingredients demon (22) Filed: Mar 14, 2014 strating an improved property, or an improved balance between two or more of properties, selected from aroma, strength, flavor, cup color, acidity, density, extractability, bed Related U.S. Application Data permeability, brewing time, yield, structural integrity, quality (60) Provisional application No. 61/793,567, filed on Mar. consistence and uniformity, and cost-effectiveness. Methods 15, 2013. of using Such coffees are also disclosed.
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COFFEE COMPOSITION FOR USE WITH A position contained within the beverage unit, which comprises BEVERAGE UNIT AND METHODS OF USING (i) providing a beverage unit comprising a container and a THE SAME coffee composition confined inside the container; (ii) intro ducing water into the container through a first structure of the CROSS REFERENCE TO RELATED container to contact the coffee composition; and (iii) releas APPLICATIONS ing a liquid coffee extract out from the container through a 0001. This application claims benefit of U.S. provisional second structure of the container. application No. 61/793,567, filed Mar. 15, 2013, hereinincor porated by reference in its entirety. BRIEF DESCRIPTION OF THE DRAWINGS 0009 Aspects of the invention are described with refer FIELD OF THE INVENTION ence to the following drawings. 0002 The present invention is related to coffee composi 0010 FIG. 1A is a side cross-sectional view of a beverage tions for use with a beverage unit Such as a cartridge, a unit wherein a coffee composition Such as an instant coffee capsule, and a pod, a method of making the same, and a composition is loaded and confined inside a beverage unit, method of using the same to prepare a beverage such as which does not include a filter member. coffee. 0011 FIG. 1B is a side cross-sectional view of a beverage unit wherein a coffee composition is loaded and confined BACKGROUND OF THE INVENTION inside a beverage unit, which includes a filter member. 0012 FIG. 1C is a side cross-sectional view of another 0003. Single serve brewing systems have been used by beverage unit wherein two coffee compositions are loaded customers for more than a decade. The systems, which typi and confined inside the beverage unit of FIG. 1B. cally include a brewer device or machine and a beverage unit 0013 FIGS. 2 and 3 illustrate gas chromatograms for containing a single serving of a brew material, are designed to strength compounds including ethyl guaiacol in the first quickly brew a single cup of coffee, tea, hot chocolate, Soup, group of embodiments as exemplified by Examples 1-3. or other hot food or beverage. Once the machine has warmed 0014 FIGS. 4 and 5 illustrate gas chromatograms for up, the user inserts the single-serving unit into the machine, burnt-rubbery compounds in the first group of embodiments places a mug under a spout, and presses the brew button. as exemplified by Examples 1-3. Within 20 to 90 seconds, the hot food or beverage is ready. 0015 FIG. 6 illustrates a gas chromatogram for good fla 0004 Such single serve brewing systems exhibit a few Vor compounds in the first group of embodiments as exem technical advantages, for example, the brewing operation is plified by Examples 1-3. very user-friendly, fast, and convenient. When these systems 0016 FIG. 7 shows a typical drying curve for a typical are used to produce coffee, the coffee beverage is relatively blend of green coffee beans having an initial moisture content fresh, because most of the single-serving units are sealed air of 11% that are air-dried on a model 42200 Wenger belt dryer tight and, consequently, the roast and ground coffee inside under 300 pound (136 kg) batch conditions in the first group should not have experienced a significant loss of flavor. The of embodiments as exemplified by Examples 4-9, wherein the seal is broken at the moment of brewing, when hot water wets blend consists of equal parts Robusta, natural Arabica, and the grounds and extracts the coffee. washed Arabica beans. 0005. However, many properties of the coffees used in 0017 FIG. 8 is a perspective view of an example of mixed these beverage units are far from satisfactory and need to be moisture instant coffee flaked aggregates in the twelfth group improved. Properties which could benefit from improvement of embodiments according to the present invention. may be those associated with the ready-to-drink coffee bev 0018 FIG. 9 is a perspective view of another example of erage produced using the single-serving unit, such as the mixed-moisture instant coffee flaked aggregates in the beverage aroma, strength, flavor, cup color, yield, brewing twelfth group of embodiments according to the present inven time, and acidity; or they may be properties associated with tion. the roast and ground coffee used in the single-serving unit, 0019 FIG. 10 an illustration of an instant coffee flake such as coffee density, extractability, bed permeability, bean having an external planar face (2) polished to a high sheen in quality, and roasting uniformity and consistency. the thirteenth group of embodiments according to the present 0006 Advantageously, the present invention provides cof invention. fee compositions for use with a single-serve or multiple-serve 0020 FIGS. 11 and 12 illustrate structured instant coffee beverage unit that improves one or more of the aforemen particles, which are non-planar but which present a plurality tioned properties, or improves the balance between two or of external planarfaces exhibiting high sheen in the thirteenth more of the aforementioned properties. group of embodiments according to the present invention. 0021 FIG. 13 is a side view of a falling stream comprised SUMMARY OF THE INVENTION of instant coffee flakes and densified instant coffee powder (8) 0007. One aspect of the invention provides for a coffee being introduced to a jet of steam (9) in the thirteenth group of composition for use in a beverage unit, wherein the beverage embodiments according to the present invention. unit comprises a container having a first structure, to enable 0022 FIG. 14 is the perspective view of a beverage unit in introduction of water into the container to contact the coffee an embodiment of the present invention, which may or may composition; and a second structure, to enable release of a not include a filter member. liquid coffee extract out of the container, wherein the liquid 0023 FIG. 14A is a side cross-sectional view of a bever coffee extract is prepared by introducing water into the bev age unit as shown in FIG. 14, which does not include a filter erage unit containing the coffee composition. member. 0008 Another aspect of the invention provides for a 0024 FIG. 14B is a side cross-sectional view of a beverage method of preparing a beverage using the above coffee com unit as shown in FIG. 14, which includes a filter member. US 2014/0370181 A1 Dec. 18, 2014
0025 FIG. 14C is a side cross-sectional view of another 0048 FIG. 21A is a side cross-sectional view of a bever beverage unit as shown in FIG. 14, which includes a filter age unit as shown in FIG. 21. member. 0049 FIG.22 is the perspective view of a beverage unit in 0026 FIG. 15 is the perspective view of a beverage unit in an embodiment of the present invention, which includes a an embodiment of the present invention, which may or may filter member. not include a filter member. 0050 FIG. 22A is a side cross-sectional view of a bever 0027 FIG. 15A is a side cross-sectional view of a bever age unit as shown in FIG. 22. age unit as shown in FIG. 15, which does not include a filter 0051 FIG. 23 is the perspective view of a beverage unit in member. an embodiment of the present invention, which includes a 0028 FIG.15B is a side cross-sectional view of a beverage filter member. unit as shown in FIG. 15, which includes a filter member. 0052 FIG. 23A is a side cross-sectional view of a bever 0029 FIG. 15C is a side cross-sectional view of another age unit as shown in FIG. 23. beverage unit as shown in FIG. 15, which includes a filter 0053 FIG. 24 is the perspective view of a beverage unit in member. an embodiment of the present invention, which may or may 0030 FIG. 16 is the perspective view of a beverage unit in not include a filter member. an embodiment of the present invention, which may or may 0054 FIG. 24A is a side cross-sectional view of a bever not include a filter member. age unit as shown in FIG. 24, which does not include a filter 0031 FIG. 16A is a side cross-sectional view of a bever member. age unit as shown in FIG. 16, which does not include a filter 0055 FIG.24B is a side cross-sectional view of a beverage member. unit as shown in FIG. 24, which includes a filter member. 0032 FIG.16B is a side cross-sectional view of a beverage I0056 FIG.25 is the perspective view of a beverage unit in unit as shown in FIG. 16, which includes a filter member. an embodiment of the present invention, which may or may 0033 FIG. 16C is a side cross-sectional view of another not include a filter member. beverage unit as shown in FIG. 16, which includes a filter 0057 FIG. 25A is a side cross-sectional view of a bever member. age unit as shown in FIG. 25, which does not include a filter 0034 FIG. 17 is the perspective view of a beverage unit in member. an embodiment of the present invention, which may or may 0058 FIG.25B is a side cross-sectional view of a beverage not include a filter member. unit as shown in FIG. 25, which includes a filter member. 0035 FIG. 17A is a side cross-sectional view of a bever I0059 FIG. 26 is the perspective view of a beverage unit in age unit as shown in FIG. 17, which does not include a filter an embodiment of the present invention, which may or may member. not include a filter member. 0036 FIG.17B is a side cross-sectional view of a beverage 0060 FIG. 26A is a side cross-sectional view of a bever unit as shown in FIG. 17, which includes a filter member. age unit as shown in FIG. 26, which does not include a filter 0037 FIG. 17C is a side cross-sectional view of another member. beverage unit as shown in FIG. 17, which includes a filter 0061 FIG. 26B is a side cross-sectional view of a beverage member. unit as shown in FIG. 26, which includes a filter member. 0038 FIG. 18 is the perspective view of a beverage unit in 10062 FIG. 27 is the schematic diagram of an exemplary an embodiment of the present invention, which may or may beverage-making system, which employs the various bever not include a filter member. age units of the present invention to prepare a beverage. 0.039 FIG. 18A is a side cross-sectional view of a bever age unit as shown in FIG. 18, which does not include a filter DETAILED DESCRIPTION OF THE INVENTION member. I0063. It should be understood that aspects of the invention 0040 FIG. 18B is a side cross-sectional view of a beverage are described herein with reference to the figures, which show unit as shown in FIG. 18, which includes a filter member. illustrative embodiments. The illustrative embodiments 0041 FIG. 18C is a side cross-sectional view of another described herein are not necessarily intended to show all beverage unit as shown in FIG. 18, which includes a filter embodiments in accordance with the invention, but rather are member. used to describe a few illustrative embodiments. Thus, 0042 FIG. 19 is the perspective view of a beverage unit in aspects of the invention are not intended to be construed an embodiment of the present invention, which may or may narrowly in view of the illustrative embodiments. In addition, not include a filter member. it should be understood that aspects of the invention may be 0.043 FIG. 19A is a side cross-sectional view of a bever used alone or in any suitable combination with other aspects age unit as shown in FIG. 19, which does not include a filter of the invention. member. 0044) FIG. 19B is a side cross-sectional view of a beverage DEFINITIONS unit as shown in FIG. 19, which includes a filter member. 0064. As used herein, “beverage” refers to a liquid sub 0045 FIG.20 is the perspective view of a beverage unit in stance intended for drinking that is formed when a liquid an embodiment of the present invention, which includes a interacts with a beverage material such the coffee composi filter member. tion of the present invention. Thus, beverage refers to a liquid 0046 FIG. 20A is a side cross-sectional view of a bever that is ready for consumption, e.g., is dispensed into a cup and age unit as shown in FIG. 20. ready for drinking, as well as a liquid that will undergo other 0047 FIG. 21 is the perspective view of a beverage unit in processes or treatments, such as filtering or the addition of an embodiment of the present invention, which includes a flavorings, creamer, Sweeteners, another beverage, etc., filter member. before being consumed. US 2014/0370181 A1 Dec. 18, 2014
0065. To “brew” a beverage as used herein includes infu beans are blended with non-dried coffee beans roasted to a Sion, mixing, dissolving, steeping or otherwise forming a Hunter L-color of from 17-24 and having a moisture content drinkable Substance using water or other beverage precursor before roasting of greater than about 7%. The blend contains (e.g., flavored or otherwise treated water, or other liquid from 1-50% of the dried dark roasted beans and from 50-99% whether heated or not) with a beverage medium. Also, refer of the non-dried roasted beans, giving a high-yield roasted ence to “water herein is to any suitable water formulation, coffee with balanced flavor. In the second group of embodi e.g., filtered, deionized, softened, carbonated, etc., as well as ments, the coffee in the coffee composition 110/130 and any other Suitable precursor liquid used to form a beverage, beverage material 120 as shown in FIGS. 1A, 1B and 1C is Such as Sweetened or flavored water, milk, etc. made from green coffee beans that are dried substantially 0066 “Instant coffee' refers to a flowable, particulate cof equally. These embodiments provide a process for preparing fee product that has been made by evaporating water from the reduced density roast coffee beans. The process comprises liquid extract of a roasted coffee, usually by concentration predrying green coffee beans to a moisture content of from and drying. Typical drying means, such as spray drying and about 0.5% to about 10% by weight, fast roasting the beans, freeze drying are known in the art. An example of instant and cooling the roasted beans. The resulting roasted beans coffee production may be found in U.S. Pat. No. 3,700,466, have a Hunter L-color of from about 14 to about 25, a Hunter which the entire disclosure is incorporated herein by refer AL-value is less than about 1.2 and a whole roast tamped bulk CCC. density of from about 0.28 to about 0.38 g/cc. The resulting roast coffee beans are more uniformly roasted than traditional Processing of Coffee Beans reduced density coffee beans. 0067. The coffee ingredient contained in the coffee com 0070. In connection to the background of the first group of position 110/130 and beverage material 120 as shown in embodiments, numerous attempts have been made in the past FIGS. 1A, 1B and 1C (as described in details in the “Beverage to make roasted coffee which has both an enhanced brew Unit' section of this application) may be independently from coffee yield (coffee brew solids per weight of roasted coffee) each other produced from any coffee beans or mixture and an acceptable brewed flavor. The extractability of roasted thereof, either in their natural state or after being subject to coffee (the amount of brew solids that can be extracted from various mechanical, physical, chemical, and/or biological a given weight of coffee from which a coffee brew is made) treatments. Coffee beans are the seeds of “cherries' that grow can be increased by grinding the roasted coffee to finer par on coffee trees in a narrow Subtropical region around the ticles sizes. These fine grinds, however, are physically diffi world. There are many coffee varieties, however, it is gener cult to brew. The fine particles are subject to pooling, chan ally recognized that there are two primary commercial coffee neling and compaction during brewing. Fine grinds also have species: Coffea arabica (herein “Arabica(s)) and Coffea an undesirable balance offlavor and strength. The extractabil canephora var. robusta (herein "Robusta(s)). Coffees from ity can also be enhanced by flaking roast and ground coffee. the species arabica may be described as “Brazils.” which Flaking involves roll milling a roast and ground coffee. More come from Brazil, or “Other Milds' which are grown in other coffee can be brewed from flaked coffee due to the increased premium coffee producing countries. Premium Arabica extractability. However, the level of container aroma offlaked countries are generally recognized as including Colombia, coffee needs to be further improved, and so does the balance Guatemala, Sumatra, Indonesia, Costa Rica, Mexico, united of flavor and strength of flaked coffee. Fast roasting of coffee States (Hawaii), El Salvador, Peru, Kenya, Ethiopia and beans can also increase brew coffee yield. Roasting times Jamaica. Coffees from the species canephora var. robusta are affect product density and extractability. Fast roasted coffee, typically used as a low cost extender, as a body enhancer, or i.e., roast times less than about 5.5 minutes, is less dense than as a source of additional caffeine for Arabica coffees. These longer roasted coffee. Despite that fast roasted coffee pro Robusta coffees are typically grown in the lower regions of vides an enhanced extractability, its balance of flavor and West and Central Africa, India, South East Asia, Indonesia, strength still needs to be improved. and Brazil. See, US 2008/0118604, of which the disclosure is 0071. The first group of embodiments can enhance incorporated herein by reference. extractability and brew coffee yield, but not at the expense of 0068. When removed from the coffee cherry, coffee beans balanced flavor of the coffee brew, as exemplified in normally have a distinctly green color and high moisture Examples 1-3. Green coffee beans are pre-dried, prior to content. In many embodiments of the invention, these beans roasting, to moisture content of from about 0.5 to about 7%. are dried to a moisture content of e.g. about 12%. Historically, The drying is conducted attemperatures of from about 70°F. Solar drying was the method of choice, although machine to about 325° F (about 21°C. to about 163°C.) for from about drying is now normally used due to the reliability and effi 1 minute to about 24 hours. The dried coffee beans are fast ciency of the machine dryers available for this purpose. See, roasted to an extreme Hunter L-color of from about 10 to Sivetz et al., Coffee Technology, “Drying Green Coffee about 16. The dried dark roasted coffee beans are blended Beans”, pp. 112-169 (1979). with non-dried roasted coffee beans having moisture content 0069. In the present invention, coffee beans may be dried before roasting of greater than about 7%. The blend com differentially or equally, before they are subject to the roast prises from about 1 about 50% of the dried dark roasted beans ing step. In the first group of embodiments, the coffee in the and from about 50 to about 99% of the non-dried roasted coffee composition 110/130 and beverage material 120 as beans. The dried dark roasted beans provide strength with shown in FIGS. 1A, 1B and 1C is made from green coffee minimal burnt-rubbery flavor notes. The non-driedbeans pro beans that are dried differentially. Some coffee beans are vide flavor and acidity. The resulting blend has a desirable pre-dried to a moisture content of from 0.5 to 7%. The drying balance of strength, flavor and acidity in a high-yield roasted is conducted at from 70° F. to 325° F (21° C. to 163°C.) for coffee. from 1 minute to 24 hours. The dried green beans are fast 0072. One aspect of the first group of embodiments pro roasted to a Hunter L-color of from 10-16. The dried roasted vides for a coffee composition for use in a beverage unit and US 2014/0370181 A1 Dec. 18, 2014
method thereofas defined in the Summary of the Invention, 0078 (a)(i) drying green coffee beans prior to roasting to wherein the coffee composition comprises high-yield roasted a moisture content of from about 0.5 to about 7% by weight, coffee with balanced flavor made from a process comprising: wherein the drying is conducted at a temperature of from 0073 (a) drying green coffee beans prior to roasting to a about 21°C. to about 163°C. for from about 1 minute to about moisture content of from about 0.5 to about 7% by weight, 24 hours; and wherein the drying is conducted at a temperature of from 0079 (a)(ii) roasting the dried beans from step (a)(i) at a about 21°C. to about 163°C. for from about 1 minute to about temperature of from about 177° C. to about 649° C. for from 24 hours; about 10 seconds to about 5.5 minutes to a Hunter L-color of 0074 (b) roasting the dried beans from drying step (a) at a from about 10 to about 16; temperature of from about 177° C. to about 649° C. for from about 10 seconds to about 5.5 minutes to a Hunter L-color of 0080 wherein the roasted coffee product has an f(1) value from about 10 to about 16; and greater than about 900, an f(2) value greater than about 1200, 0075 (c) blending the dried roasted beans from roasting and an f(3) value greater than about 125, where step (b) with non-dried coffee beans roasted to a Hunter f(1)=10,000xpyrazine-pyridine-pyrrole-guaiacol ethyl guaiacol 3-thiazole+4-methylthiazole+ L-color of from about 17 to about 24 and having a moisture peak 13+peak 14+peak 15+tetrahydrothiophene-- content before roasting of greater than about 7% by weight, peak 17+2-thiophenecarboxaldehyde--peak wherein the blend comprises from about 1 to about 20% by 19+3-acetylthiophene-2-acetylthiophene-peak weight of the dried roasted beans and from about 80 to about 22, 99% by weight of the non-dried roasted beans; wherein the resulting roasted coffee blend has an improved brew yield of f(2)=100xethyl guaiacol, and from about 30 to about 40%. f(3)=100xethanal+propanal+2-pentanone-3-pen 0076. In more specific examples under this aspect, the tanone-2,3-pentanedione pyrazine-pyridine dried roasted coffee beans from roasting step (b) may have a pyrrole-guaiacol--ethyl guaiacol: Hunter L-color of from about 12 to about 16. The blend of dried roasted coffee beans and non-dried roasted coffee beans I0081 wherein the brewed acidity index is greater than from blending step (c) may comprise from about 5 to about about 2200, where brewed acidity index=1000xvolume (ml) 15% by weight of the dried roasted coffee beans and from of 0.1 Normal sodium hydroxide added to 150 grams of about 85 to about 95% by weight of the non-dried roasted coffee brew to adjust the pH of the brew to 7.00, and coffee beans. The dried green coffee beans in drying step (a) 0082 wherein the roasted coffee product has an improved may be selected from the group consisting of low quality brew yield of from about 30 to about 100%. coffee beans, intermediate quality coffee beans and mixtures thereof, and the non-dried coffee beans in blending step (c) I0083. In more specific examples under this aspect, the may be selected from the group consisting of intermediate dried dark roasted coffee from (a) may have a Hunter L-color quality coffee beans, high quality coffee beans and mixtures of from about 12 to about 16. The coffee product may com thereof. The dried green coffee beans in drying step (a) may prise from about 5 to about 15% by weight of the dried roasted be Robustas. The dried green coffee beans in roasting step (b) coffee from (a) and from about 85 to about 95% by weight of may be roasted at a temperature of from about 204°C. to the non-dried roasted coffee from (b). The dried dark roasted about 427°C. for from about 1 to about 3 minutes. The drying coffee from (a) is derived from coffee beans selected from the in drying step (a) may be conducted at a temperature of from group consisting of low quality coffee beans, intermediate about 71° C. to about 121° C. for from about 1 to about 6 quality coffee beans, and mixtures thereof, and the non-dried hours. The green coffee beans may be dried in drying step (a) coffee from (b) is derived from coffee beans selected from the to a moisture content of from about 3 to about 7% by weight. group consisting of high quality coffee, intermediate quality Moreover, the process may further comprise the steps of (i) coffee, and mixtures thereof. The dark roasted coffee from (a) flaking the blend of dried roasted and non-dried roasted cof may be derived from Robusta beans. The roasting in step fee beans in blending step (c) to an average flake thickness of (a)(ii) may be conducted at a temperature of from about 204° from about 102 to about 1016 um (e.g. from about 102 to to about 427°C. for from about 1 to about 3 minutes. The about 254 um); (ii) blending the flaked coffee with roast and drying in step (a)(ii) may be conducted at a temperature of ground coffee, wherein the blend of flaked coffee and roast from about 71° to about 121° C. for from about 1 to about 6 and ground coffee comprises from about 10 to about 50% hours. The green coffee beans may be dried in step (a)(ii) to a (e.g. from about 25 to about 50%) by weight flaked coffee and moisture content of from about 3 to about 7% by weight. from about 50 to about 90% (e.g. from about 50 to about 75%) I0084 With respect to the first group of embodiments, as by weight roast and ground coffee. described above, as exemplified by Examples 1-3, and as 0077. Another aspect of the first group of embodiments illustrated in FIGS. 2-6, three steps are important. A first step provides for a coffee composition for use in a beverage unit involves drying green coffee beans. A second step involves and method thereofas defined in the Summary of the Inven fast roasting the dried beans to an extremely dark roast. A tion, wherein the coffee composition comprises a roasted third step involves blending the dried dark roasted beans with coffee product including from about 1 to about 20% dark roasted non-dried coffee beans. roasted coffee as the first component and from about 80 to about 99% coffee roasted to a Hunter L-color of from about I0085. The coffee product used in the first group of embodi 17 to about 24 and derived from green coffee beans having a ments contains a unique and critical balance of strength and moisture content prior to roasting of greater than about 7% as good flavor compounds and acidity. the second component, based on the total weight of the first I0086. As used in the first group of embodiments, all per component and the second component, wherein said dark centages and ratios are based on weight unless stated other roasted coffee is made by the process comprising: wise. US 2014/0370181 A1 Dec. 18, 2014
I0087 A) Drying Green Coffee Prior to Roasting in the (0098 C) Blending Dried and Non-Dried Coffee Beans in First Group of Embodiments the First Group of Embodiments 0088. In the drying step, green coffee beans having an 0099. The dried dark roasted coffee beans are blended initial moisture content greater than about 10%, preferably with non-dried roasted coffee beans. The dried beans provide from about 10 to about 14%, are dried prior to roasting. The strength with minimal burnt-rubbery flavor notes. The non dried beans have a moisture content of less than about 7%, dried beans provide flavor and acidity. The blend comprises preferably from about 3 to about 7%. from about 1 to about 50%, preferably from about 1 to about 20%, most preferably from about 5 to about 15% of the dried 0089. The drying in the first group of embodiments should beans and from about 50 to about 99%, preferably from about be conducted under gentle conditions. Large heat inputs and 80 to about 99%, most preferably from about 85 to about 95% temperature differentials can result in tipping, burning or of the non-dried beans. premature roast-related reactions of the coffee beans. The 0100. The non-dried beans are derived from green coffee green beans are dried in an apparatus containing from 0 to beans having moisture content prior to roasting of above 70% moisture. Drying temperatures are from about 70° F. to about 7%, preferably from about 10 to about 14%. These about 325° F (about 21 C. to about 163°C.), preferably from green beans are not subjected to the drying step prior to about 160F. to about 250° F (about 71°C. to about 121°C.). roasting. The non-dried green coffee beans are roasted, pref Drying times are from about 1 minute to about 24 hours, erably fast roasted, to a Hunter L-color of from about 17 to preferably from about 2 to about 6 hours. about 24. The non-dried roasted beans have tamped densities 0090 The drying step results in partially dehydrated cof of from about 0.28 to about 0.42 grams/cc. fee beans without causing significant roasting-related reac 0101 Both the dried and non-dried beans according to the tions to take place. Roasting reactions are described in Sivetz first group of embodiments can be derived from low, inter et al., “Coffee Technology’. AVI Publishing Company, West mediate or high quality coffee beans, or mixtures thereof. port, Conn., pp. 250-262 (1979), herein incorporated by ref Preferably the dried beans are derived from intermediate or CCC. low quality beans or mixtures thereof, more preferably from 0091. In the first group of embodiments, drying methods low quality coffee beans, most preferably from Robustas. The and apparatuses for use in the drying step are disclosed in U.S. non-dried beans are preferably derived from intermediate or Pat. No. 5,160,757 to Kirkpatricket al., which is herein incor high quality beans or mixtures thereof. porated by reference. 0102. As used in the first group of embodiments, non limiting examples of high quality coffee beans include 0092. After the coffee beans are dried, they are subjected “Milds’ (high grade Arabicas) such as Colombians, Mexi to a roasting step described hereinafter. The coffee beans cans, and washed Milds such as strictly hard bean Costa Rica, should have minimal contact, preferably no contact, with Kenyas A and B, and strictly hard bean Guatemalans. As used moisture between the drying and roasting steps. in the first group of embodiments, non-limiting examples of 0093 B) Dark Roasting Dried Coffee Beans in the First intermediate quality coffee beans include Brazilians and Afri Group of Embodiments can naturals. As used in the first group of embodiments, 0094. In the roasting step, the dried coffee beans are dark non-limiting examples of low quality coffee beans include roasted to a Hunter L-color of from about 10 to about 16, Robustas, low grade Naturals, low grade Brazils, and low preferably from about 12 to about 16, most preferably from grade unwashed Arabicas. about 14 to about 16. The dried dark roasted beans have 0103. It has been found that flavor strength in the coffee tamped densities of from about 0.28 to about 0.42 grams/cc. blends can be derived from relatively few coffee beans. In the 0095 Conventional fast roasting methods can be used in blended coffee, the high-strength beans (dried dark roasted the first group of embodiments. Roasting temperatures are beans) preferably represent only from about 5 to about 15% of from about 350° F. to about 1200° F (about 177° C. to about the blended beans. This small fraction ofbeans has a high f(1) 649° C.), preferably from about 400° F to about 800° F. value (ratio of strength compounds to burnt-rubbery com (about 204°C. to about 427°C.). Roast times are from about pounds) and a low f(2) value (amount of good flavor com 10 seconds to about 5.5 minutes, preferably from about 1 to pounds). These values are listed in Table 1 and described about 3 minutes. Fast roasting is described in U.S. Pat. No. hereinafter. 5,160,757 to Kirkpatricket al. Fast roasting is also described 0104 Very small amounts of these dried dark roasted in Sivetz, Coffee Technology, AVI Publishing Company, beans can now be added to weak but flavorful coffees (i.e., Westport, Conn., pp. 226-246 (1979), which is herein incor high quality coffee such as Colombian). The result is a fla porated by reference. vorful, full-strength coffee unadulterated by excessive burnt rubbery flavor notes. 0096. At the desired Hunter L-color, the dark roasted 0105 D) Admixture of Flakes and Roast and Ground Cof beans are removed from the roaster heat. The beans are fee in the First Group of Embodiments promptly cooled by typically ambient air and/or a water 0106 Optionally, the blend of roasted dried and non-dried spray. Cooling the beans stops roast-related pyrolysis reac coffee beans are ground, normalized and milled to an average tions. flake thickness of from about 102 to about 1016 um (about 0097. In the first group of embodiments, roasting the dried 0.004 to about 0.04 inches), preferably from about 102 to beans to the darker Hunter L-colors develops strength com about 508 um (about 0.004 to about 0.002 inches), most pounds with minimal development of burnt-rubbery flavor preferably from about 102 to about 254 um (about 0.004 to compounds. The specific compounds are defined hereinafter. about 0.01 inches). Flaked coffees are described in: U.S. Pat. Dark roasting non-dried coffee beans, especially low quality Nos. 5,064,676; 4,331,696; 4,267,200; 4,110,485; 3,660,106; beans such as Robustas, to these extremes would result in 3,652.293; and 3,615,667, all of which are herein incorpo excessive burnt-rubbery flavor notes. rated by reference. US 2014/0370181 A1 Dec. 18, 2014
0107 Additionally, the flaked blend can be admixed with 0115 The Table 1 coffees are defined as follows. These roast and ground coffee. The admixture comprises from about coffees can now all be used in the beverage units according to 10 to about 50%, preferably from about 25 to about 50% of the present invention, for example, the first group of embodi the flaked blend and from about 50 to about 90%, preferably ments thereof. Vacuum Folgers is a 13 ounce, automatic drip from about 50 to about 75% of the roast and ground coffee. grind (ADC) coffee manufactured by The Procter & Gamble The roast and ground coffee comprises the non-dried roasted Company, code date 2133N. Maxwell House Master Blend is beans, the dried roasted beans, or mixtures thereof, preferably an 11.5 ounce, ADC coffee manufactured by General Foods, the non-dried roasted beans. code date 2054. Folgers French Roast is a 12 ounce, dark 0108. It was found that thin flaking the dried dark roasted coffee beans, or blends containing the dried beans, results in roast, ADC coffee made by The Procter & Gamble Company, a Surprisingly dark cup color. Flaking increases brew solids code date 2106. Chock Full of Nuts Ultra Roast is an FAC (for by about 20% but increases cup color by about 40%. Cup all coffeemakers) coffee manufactured by Chock Full of Nuts color is important to consumer perceptions. Although cup Corp., code date 1N20. Splendid Italian Expresso is a 17.6 color per se does not contribute to coffee flavor or strength, ounce, fine grind coffee manufactured by The Procter & brewed coffee with darker colors are perceived as having Gamble Company, code date Mar90. The dried and non-dried richer, stronger flavors. coffees are the components of the 10:90 blend. The blend is a 0109 E) Characteristics of the Coffee Product in the First high-yield, balanced flavor coffee of the first group of Group of Embodiments embodiments. 0110. The coffee product of the first group of embodi ments has a unique chemistry profile. The unique chemistry 0116 2) Balanced Flavor Benefit provides a balanced flavor and a high yield. 0117 The chemistry profile of the coffee product in the 0111 1) Chemistry Profile first group of embodiments provides a balanced flavor to 0112 The chemistry profile of the coffee product is coffee brews. Other coffee products have from Zero to two of defined by f(1), f(2), and f(3) values wherein f(1) is greater the f(1), f(2) or f(3) values in the ranges recited herein. How than about 900, f(2) is greater than about 1200 and f(3) is ever, it is the combination of all three values at the recited greater than about 125. These values are determined as fol levels that is important. lows. 0118. In the first group of embodiments, f(1) relates flavor f(1)=10,000x strength compounds burnt-rubbery strength to burnt-rubbery flavor. It is desirable to achieve a compounds high f(1) value especially in high-yield coffee (i.e., low den ft2)=100xethyl guaiacol sity, fast roasted coffee). High-yield coffees often have increased flavor strength and increased burnt-rubbery flavor. f(3)=100xgood flavor compounds/flavor strength The coffee product in the first group of embodiments has compounds increased flavor Strength but only minimal increased burnt Strength compounds pyrazine-pyridine-pyrrole-- rubbery flavors. The dried dark roasted beans provide this guaiacol--ethyl guaiacol benefit to the coffee product. Burnt-rubbery compounds=3-thiazol-4-methylthiaz 0119. In the first group of embodiments, f(2) relates to ole+peak 13+peak 14+peak 15+tetrahy ethyl guaiacol levels. Ethyl guaiacol provides flavor strength. drothiophene-peak 17+2-thiophenecarboxalde The high f(2) value indicates a selectively developed strength hyde--peak 19+3-acetylthiophene-2- acetylthiophene-peak 22. component from the dried roasted coffee beans. I0120 In the first group of embodiments, f(3) relates good Good flavor compounds ethanal+propanal+2-pen flavor to flavor strength. It is desirable to increase f(3) to tanone-3-pentanone-2,3-pentanedione. develop a balance of good flavor with increased flavor 0113 Individual compounds are measured in terms of strength. The good flavor arises from the non-dried roasted total gas chromatograph (GC) counts. Methods for measuring coffee beans. The flavor strength arises from the dried dark GC counts for each of the three compound groups (strength, roasted coffee beans. good flavor, burnt-rubbery) are described hereinafter. The unknown “peak’ compounds are defined hereinafter. I0121 3) High Yield Benefit 0114. The chemistry of the coffee product used in the first I0122. It was found that the coffee product in the first group group of embodiments is unique when compared to conven of embodiments has a Surprisingly high yield. As used herein, tional and/or dark roasted coffee. As shown in Table 1, only "yield’ means the weight in grams of a roasted coffee needed the coffee product has the critical combination of f(1), f(2) to brew one cup of coffee. Yields for various coffees are listed and f(3) values. in Table 2. TABLE 1. Vacuum Maxwell House Chock Full of French Splendid Italian Dried Non-Dried Blend of the Dried (10%) Function Folgers Master Blend Nuts Ultra-Roast Roast Expresso Roasted Coffee Roasted Coffee and Non-Dried (90%) coffee f(1) 710 1OOO 870 940 1320 4300 700 1060 f(2) 770 835 1060 750 2140 7600 1OOO 1660 f(3) 310 150 210 220 50 95 2OO 190 US 2014/0370181 A1 Dec. 18, 2014
TABLE 2 are added to the flask. The preferred internal standard is isoamyl acetate (5 mcl) dissolved in methylene chloride to Weight of roasted coffee needed to make 100 ml. Contents of the flaskare then processed into an Coffee type (weight per 1000 cc make one cup of brewed coffee SDE extract. The extract (3 mcl) is injected on to the column. volume of roasted coffee) (grams, cup) The GC oven is maintained at 25°C. (77°F) for 2.6 minutes. Conventional roast and ground The oven temperature is raised 20°C./min. to 45° C. (113°F) coffees: and then held for 7 minutes, raised again at 3.0°C./min. to 65° 16 ounce coffee S.16 C. (149°F) and then held for 6 minutes, raised again at 2.0° 13-ounce coffee 4.2O C./min. to 125° C. (257° F.) and held for 1 minute, raised 11.5-ounce coffee* 3.71 again at 3.0° C./min. to 220° C. (428° F.) and held for 6 10.5-Ounce coffee* 3.39 High-yield coffee in the first group of minutes, and finally raised to 230°C. (446°F) and held for 30 embodiments: minutes.
(13-ounce)* 2.58 Conditions for the HP-CGC *fast roasted, low density coffee Septum purge flow 1 cc/min. 0123. The roasted coffee product of the first group of Inlet pressure 26 psig embodiments yields from about 30 to about 100% more Went flow 30 cc min. brewed coffee. It also yields from about 30 to about 63% more Make-up carrier flow 30 cc min. brewed coffee than other low density, fast roasted coffee. The Flame Ionization Detector: phrase “cup of brewed coffee' in Table 2 means coffee brews Hydrogen flow rate 30 cc min. that, with respect to organoleptic properties, are similar to or Air flow rate 400 cc./min. better than that of conventionally brewed roast and ground Column flow 3 cc./min. coffee. Split ratio 10.1 0.124. This high-yield coffee can be combined with soluble coffees or admixed with non-coffee materials. It can 0.133 FIGS. 2 and 3 are gas chromatograms from the be caffeinated or decaffeinated. It can also be added to filter SDE-CGC analytical method using SDE extract obtained packs or used to manufacture soluble coffee. from the roasted coffee in the first group of embodiments. 0125 4) Acidity Peaks are labeled 6 to 10 which correspond to pyrazines (6), 0126 Brewed coffee from the coffee product has a brewed pyridines (7), pyrroles (8), guaiacols (9), and ethyl guaiacols acidity index of above about 2200. The brewed acidity index (10). described hereinafter is the expression of coffee acidity used I0134. The chromatogram is analyzed by determining the herein. Brewed coffee with a brewed acidity index of less than area of each recorded peak. The peaks are proportional to the about 2200 lacks the acidity, which is necessary for accept GC counts (digitized electrical impulses proportional to GC able coffee flavor. peak areas). 0.135 Total GC counts as used herein are corrected GC Analytical Methods in the First Group of Embodiments counts. GC counts of each peak of a sample extract are nor 0127 A) Analysis of Strength Compounds Including malized (corrected) to make all of the sample extracts on the Ethyl Guaiacol same basis for comparison by ratioing the GC counts of each 0128 1) Analytical Method peak to the GC counts of the internal standard. 0129. The simultaneous steam distillation and extraction 0.136 Corrected GC counts for a given compound are cal (SDE) method disclosed by Schultz et al., J. Agric. Food culated using the following equation: Chem. 25, 446-449 (1977), followed by capillary gas chro matography (CGC) of an SDE extract, is used to analyze the flavor strength compounds including ethyl quaiacol. The Corrected GC Counts = combined SDE-CGC method is disclosed in U.S. Pat. No. Area of a GC Peak 4,857,351 to Neilson et al., issued Aug. 15, 1989, which is Area of the Internal Standard Peak XResponse Factorx Dilution Factor herein incorporated by reference. 0130. An SDE extract (0.3 ml) is obtained from a roast and ground coffee by the SDE method described in U.S. Pat. No. 0.137 Response factors for specific compounds include 4,857,351. The extract is analyzed with a Hewlett-Packard pyrazine (1.200), pyridine (0.660), pyrrole (0.950), guaiacol 5880A Capillary Gas Chromatograph (HP-CGC). The HP (0.740) and ethyl guaiacol (1.000). CGC has a fused silica column (DB5 column, 60 meter 0.138 B) Analysis of Burnt-Rubbery Compounds length, 0.32 mm internal column diameter, from J&W Scien 0.139. This method is used to analyze burnt-rubbery com tific, Inc. of Cardova, Calif.) and a flame ionization detector pounds. It is similar to that used in analyzing the flavor (FID) to detect the carbon and hydrogen of the volatile com strength compounds. Differences in the two methods are pounds in the SDE extract. The column contains a film of described below. crosslinked polyethylene glycols 1.0 um thick. A Hewlett 0140. The SDE extract is analyzed by a HP-CGC and a Packard Level Four data terminal is used to process the data Supelcowax-10 fused silica column (Supelo, Inc. of Belle for retention times, peak areas and area percents. fontaine, Pa.). The column is used with a flame photometric 0131) 2) Application of the Analytical Method detector (FPD) to detect volatile sulfur compounds (i.e., 0132 Roast and ground coffee (5.0 grams) is placed in a burnt-rubbery compounds) in the SDE extract. 500 cc round bottom flask. Distilled water (200 grams) is 0.141. In making the SDE extract, the preferred internal added to the flask. Internal standard (3 ml) and boiling stones standard is 2,5-dimethyl thiophene dissolved in methylene US 2014/0370181 A1 Dec. 18, 2014
chloride (10 mcl diluted to 25 ml in a first dilution, then 6 ml 0156 Flame Ionization Detector: diluted to 200 ml in a second dilution). O157 Temperature: 482°F. (250° C.) 0142. The SDE extract is injected on to the column. The 0158 Hydrogen flow rate: 30 cc/min. GC oven is maintained at 50° C. for 3.00 minutes. The oven 0159 Air flow rate: 300 cc/min. temperature is raised 2.0°C./min. to 100° C. and then held for 15 minutes, raised again at 1.00° C./min. to 130° C. and then (0160 Chart speed: 0.5 cm./min. held for 1 minute, and then raised to 201° C. and held for 5 0.161 The chromatogram analysis is the same as that used minutes. in the analysis of flavor strength and good flavor compounds. 0143 FIGS. 4 and 5 are gas chromatograms from this 0162 FIG. 6 is a gas chromatogram of this method using method using SDE extract obtained from the roasted coffee of extract derived from roasted coffee from the first group of the first group of embodiments. The peaks are labeled 11 to 22 embodiments. The peaks are labeled 1 to 6 which correspond which correspond to 3-thiazole (11), 4-methylthiazole (12), to ethanal (1), propanal (2), 2-pentanone (3), 3-pentanone (4) peak 13 (13), peak 14 (14), peak 15 (15), tetrahydrothiophene and 2,3-pentanedione (5). (16), peak 17 (17), 2-thiophenecarboxaldehyde (18), peak 19 0163. In calculating corrected GC counts, the response (19), 3-acetylthiophene, 2-acetylthiophene and peak 22. factors include ethanal (71.59801), propanal (29.16200), 0144. The response factor is 1 for each of the burnt-rub 2-pentanone (18.42800), 3-pentanone (15.77300) and 2.3- bery compounds. pentanedione (41.89000). 0145 C) Analysis of Good Flavor Compounds 0164 C) Measuring Acidity 0146) 1) Analytical Method 0.165 Brewed acidity index relates to the acidity of brewed 0147 Programmed temperature GC analysis is used to coffee. Brewed coffee typically has a pH of from about 4 to 5. analyze the good flavor compounds. Sodium Sulfate and an The brewed acidity index is a more discriminating acidity internal standard are added to a brewed coffee inside a closed scale than logarithmic based pH units. system and heated. A headspace sample from the heated (0166 The brewed acidity index=1000xvolume (ml) of 0.1 combination is injected into a Varian model 3400 Gas Chro Normal sodium hydroxide added to 150 grams of coffee brew matograph (DB-1701 column, 30 meter length, 0.32 mm to raise its pH to 7.00. The coffee brew is prepared from 31.2 internal column diameter, from J&W Scientific of Folsom, grams of roasted coffee particles and 1420 ml of distilled Calif.). The column contains a film of crosslinked polyethyl water in a conventional automatic drip coffeemaker. ene glycols 1.0 um thick. 0.167 As described previously, the coffee beans in the 0148 2) Application of Analytical Method present invention may be dried differentially or equally, 0149 Sodium sulfate (13.00+0.03 grams) is placed in a before they are subject to the roasting step. In the second 120 cc septum bottle. A roast and ground coffee sample group of embodiments, the coffee in the coffee composition (13.00+0.01 grams) is added to the bottle followed by deion 110/130 and beverage material 120 as shown in FIGS. 1A, ized water (65 ml) and internal standard (1 ml). 1B, and 1C is made from green coffee beans that are dried 0150. The internal standard is made by the following Substantially equally. Specifically, the coffee composition in operation. A 1000 cc volumetric flask is filled with distilled the second group of embodiments comprises coffee made water to within 5-10 cm of the 1000 cc calibration mark. With from reduced density roast coffee beans. The process for a pipet, 1 ml of regent grade ethyl acetate is added to the flask. preparing Such beans comprises pre-drying green coffee The ethyl acetate should be dispensed into the flask by low beans to moisture content of from about 0.5% to about 10% ering the tip of the pipet just below the surface of the water by weight, fast roasting the beans, and cooling the roasted and tipping the flask (and pipet) slightly so that when the ethyl beans. The resulting roasted beans have a Hunter L-color of acetate is released, the droplets will rise to the surface free of from about 14 to about 25, a Hunter AL-value is less than the pipet. When the ethyl acetate has stopped flowing, the about 1.2 and a whole roast tamped bulk density of from about pipet is raised inside the flask neck and the final few drops are 0.28 to about 0.38 g/cc. The resulting roast coffee beans are “tipped off.” The flask is stoppered, inverted, and agitated by more uniformly roasted than traditional reduced density cof Swirling and inverting it 5-10 times. Agitation is stopped and fee beans. the air bubbles are allowed to rise. Distilled water is added to 0.168. In connection to the background of the second group make 1000 ml. The liquid is again agitated. The resulting of embodiments, roast and ground coffee has been marketed internal standard within the flask contains 1000 ppm (v/v) on Supermarket shelves by weight in 16-ounce cans. How ethyl acetate. ever, a later trend in the coffee market has resulted in the 0151. After adding the internal standard, the bottle is demise of the 16-ounce weight standard, and major coffee sealed with a septum. A 2 cc gas Syringe and the sealed bottle manufacturers began marketing 13-ounce blends. The blends are placed into a Blue M oven (Model SW-11TA) for 45 were prepared using “fast roast” technology that resulted in a minutes at 90° C. The bottle is removed from the oven. A lower density bean. Thirteen ounces of these lower density needle attached to the heated Syringe is inserted through the blends have nearly the same volume as the traditional septum to a level halfway between the top of the bottle and the 16-ounce blends. As a result they could be marketed in the old surface of the liquid therein. Headspace (2 ml) is removed and 1-pound cans and were priced about 20 cents below the pre injected into the gas chromatograph. vious 16-ounce list price because they used fewer beans. This 0152 The initial temperature of the column oven is 100° down-weighting of coffee in cans has met with widespread C. for 5 minutes, raised 4°C./minute to 115° C. and then held acceptance in the industry. Many “fast roast' coffees also for 7 minutes, and finally raised 7°C./min. to 200° C. and then have a higher yield of brew solids than previous 16-ounce held for 2 minutes. coffees. These high yield fast roast and ground coffees exhibit 0153. GC conditions are: improved extraction characteristics during brewing. Thus, 0154 Carrier gas: helium 2.5 cc/min. they can make as many cups of coffee (or more) per 13 ounces (O155 Injection port temperature: 646° F (240° C.) as were previously prepared from 16 ounces. US 2014/0370181 A1 Dec. 18, 2014
0169 Fast roasting results in a puffed or somewhat popped and method thereofas defined in the Summary of the Inven bean. Fast roasting of coffee typically occurs in large multi tion, wherein the coffee composition comprises a coffee stage roasters (e.g., Probat, Thermalo, Jetzone, etc.) with very made from reduced density roasted coffee beans, which are large heat inputs. These high heat inputs result in the rapid produced by a process comprising the steps of: expansion of the roasted bean. However, some aspects of the (a) first, drying green coffee beans to a moisture content of fast roast processing still need to be improved. The high heat from about 0.5% to about 7% by weight, wherein the drying inputs necessary to puff the bean result in a high degree of is conducted at a temperature of from about 70° F. to about bean roasting variation within the roaster. Also, tipping and 325° F. for at least about 1 minute; then burning of the outer edges of the bean are a major problem. (b) roasting the dried beans at a temperature of from about 0170 The second group of embodiments according to the 350° F to about 1200° F. for from about 10 Seconds to not invention uses a reduced density roast coffee bean that is more longer than about 5.5 minutes; and then uniformly roasted. The roast beans also exhibit less bean-to (c) cooling the roasted beans, wherein the resulting roast bean color variation; less color variation within each bean: beans have: and less tipping and burning of the outer edges of the roasted (0177 (1) a Hunter L-color of from about 14 to about 25: bean. 0.178 (2) a Hunter A L-color of less than about 1.2; and 0171 With respect to the moisture content of exported 0179 (3) a whole roast tamped bulk density of from about green beans, Sivetz et al., Coffee Technology, "Drying Green 0.27 to about 0.38 g/cc. Coffee Beans”, pp. 112-169 (1979), states that coffee beans 0180. In more specific examples under this aspect, the are dried prior to export. Historically, Solar drying was the drying step (a) may be conducted for from about 1 minute to method of choice. However, improved reliability and effi several months. The drying step (a) may be conducted at from ciency of machine dryers has led to their widespread use in about 120° F to about 275° F. for from about 1 hour to about the industry. The standard moisture target prior to export is 24 hours, e.g. from about 160°F to about 250° F (about 71° about 12%. Sivetz also highlights the irreversible damage C. to about 121°C.) for from 1 to 6 hours. The coffee beans in overdrying can have on coffee quality. the process may be decaffeinated or non-decaffeinated. The 0172. With respect to the effect of green bean moisture roasting step (b) may be conducted at a temperature of from content on roasted density, Sivetz et al., Supra, "Coffee Bean about 400°F. to about 800° F for from about 10 seconds to Processing, pp. 254-6 states that the bulk density of roasted about 3 minutes. The dried green coffee beans may have bean will vary with degrees of roast, speed of roast, and moisture content of from about 3% to about 6% after step (a). original moisture content of the greenbeans. Sivetz goes onto The whole roast tamped bulk density of the roasted beans is say: “Mast roasts on large beans, especially new-crop coffees from about 0.30 to about 0.35gmfcc. The process may further with more than average moisture, may cause a 10-15% larger comprise a step of (d): grinding the cooled beans to an average Swelling than normal.' (Emphasis added) particle size of from about 300 to about 3000 um. The process 0173. In a discussion of bean roasting, Clifford, Tea and may even further comprise a step of (e): flaking the ground Coffee Trade Journal, “Physical Properties of the Coffee beans. Bean’, pages 14-16, April 1986, states “Production of carbon 0181. The second group of embodiments will be further dioxide, and its expansion along with water vapor, generate described in the following, exemplified by Examples 4-9, and internal pressures in the range of 5.5 to 8.0 atmospheres and as illustrated in FIG. 7. All percents and ratios used in the account for the swelling of the bean by some 170 to 230%. second group of embodiments are on a weight basis unless (0174 U.S. Pat. No. 4.737,376, Brandleinet al., issued Apr. otherwise indicated. 12, 1988, describes a two-stage bubbling bedroasting process for producing low density (0.28 to 0.34 g/cc) coffee. During Definitions in the Second Group of Embodiments Stage 1 the beans are heated at 500°F. to 630° F (260-332° C.) for from 0.25 to 1.5 minutes at atmospheric pressure. 0182. The term “reduced density coffee' relates to roasted During State 2 the beans are heated at a temperature equal to coffee which has a roasted whole bean tamped density of or less than Stage 1 for from 0.25 to 1.5 minutes at atmo from about 0.28 to 0.38 gm/cc. spheric pressure. The 376 patent discusses the importance of 0183 The term “1-pound coffee can relates to a coffee retaining a high internal bean moisture. It is stated that high container which has a volume of 1000 cc. Historically, one internal bean moisture promotes hydrolysis reaction and pound (16 oz.) of coffee was sold in this volume container. allows the beans to remain more pliable during roasting. This 0.184 The term “pre-drying relates to a green bean mois is said to allow for greater expansion of the bean during ture removal operation which occurs prior to roasting, typi roasting. Typically, the beans fed into the Stage 1 roaster have cally, less than 1 day prior to roasting. a moisture content of 10+2%. 0185. Terms “tipping and “burning relate to the charring 0.175. In the second group of embodiments according to of the ends and outer edges of a bean during roasting. Tipping the invention, the process for producing reduced density and burning of beans results in a burnt flavor in the resulting roasted coffee beans comprises the steps of (1) pre-drying brewed beverage. green coffee beans to moisture content of from about 0.5% to 0186 The term “density” refers to tamped bulk density, about 10% by weight, (2) fast roasting the beans; and (3) i.e. the overall density of a plurality of particles measured cooling the roasted beans. The resulting roasted beans have a after vibratory settlement. Hunter L-color of from about 14 to about 25, a Hunter AL 0187. The term “percent moisture' relates to the amount color of less than about 1.2 and a whole roast tamped bulk of water in a greenbean, a roasted bean or roasted and ground density of from about 0.28 to about 0.38 g/cc. The product bean on a wet-basis. Moisture content is determined by oven beans can be ground or ground and flaked after roasting. drying. First, the material is ground to a mean particle size of 0176 One aspect of the second group of embodiments about 900 um. Tengrams of ground material is then weighed provides for a coffee composition for use in a beverage unit into a drying dish and placed in a 105° C. drying oven for 16 US 2014/0370181 A1 Dec. 18, 2014
hours. The weight loss from the sample represents the mois the dryer. Air flow can be parallel to counter-current to the ture in the original sample and, accordingly, is used to calcu beans. Rotary dryers suitable for use in the second group of late the percent moisture. embodiments include those manufactured by APV Crepaco. 0188 Pre-Drying of Coffee Prior to Roasting in the Sec Inc., Tonawanda, N.Y.; Aeroglide Corp., Raleigh, N.C.; ond Group of Embodiments Blaw-Knox Food & Chemical Equipment Co., Buflovak 0189 It has been discovered that reduced density coffee Division, Buffalo, N.Y.; and Littleford Bros. Inc., Florence, can be produced from green coffee beans having a moisture Ky. content of less than about 10%. However, it also contem 0.197 Belt dryers suitable for use in the second group of plated in the second group of embodiments that high levels of embodiments include those manufactured by APV Crepaco, moisture and the resulting steam expansion in the bean during Inc., Attleboro Falls, Mass.: The National Drying Machinery rapid roasting may be responsible for the Swelling/puffing Co., Philadelphia, Pa.; C. G. Sargent's Sons Corp., Westford, that results in a reduced density bean. Mass.: Aeroglide Corp., Raleigh, N.C.; and Proctor & (0190. Without being bound to theory, it is believed that Schwartz, Inc., Horsham, Pa. Chamber dryers suitable for use water is a possible contributor to coffee swelling/puffing, but in the second group of embodiments include those manufac not at the high levels discussed in the prior literature. tured by Wyssmont Company, Inc., Fort Lee, N.J. Continuous 0191 In the process of the second group of embodiments, conveyor dryers Suitable for use in the second group of green coffee beans having an initial moisture content greater embodiments include those manufactured by APV Crepaco, than about 10%, preferably greater than about 10% to about Inc., Attleboro Falls, Mass.: The National Drying Machinery 14%, most preferably greater than about 10% to about 12%, Co., Philadelphia, Pa.; C. G. Sargent's Sons Corp., Westford, are first dried to a moisture content of from about 0.5 to about Mass.: The Witte Co., Inc., Washington, N.J.; Wyssmont 10%, preferably from about 2% to about 7%, more preferably Company, Inc., Fort Leed, N.J.; Proctor & Schwartz, Inc., from about 2% to about 6%, more preferably from about 3% Horsham, Pa.; Wenger Mfg. Inc., Sabetha, Kans.: Werner & to about 6%, and most preferably about 3% to about 5%. Pfleiderer Corp., Ramsey, N.J.; and Wolverine Corp., Merri 0192 The drying stage, according to the second group of mac, Mass. Convective dryers suitable for use in the second embodiments, results in partially dehydrated coffee bean group of embodiments include those manufactured by APV without causing any significant roasting-related reactions to Crepaco, Inc. Tonawanda, N.Y.: The National Drying take place. Roasting reactions are described in Sivetz, Supra, Machinery Co., Philadelphia, Pa.; Wyssmont Company, Inc., pp. 250-262, incorporated herein by reference. Fort Lee, N.J.; Proctor & Schwartz, Inc., Horsham, Pa.; and (0193 Without being bound by theory, it is believed that Wenger Mfg. Inc., Sabetha, Kans. the key to the pre-drying step of the second group of embodi ments is that the moisture content of the resulting beans is 0198 The drying step in the second group of embodiments relatively uniform throughout the bean, i.e. the moisture pro should be conducted under gentle conditions. Large heat file within the beans has equilibrated. Accordingly, the inputs and temperature differentials can result in tipping and method of pre-drying is not critical, provided the moisture burning of the bean or premature roast-related reactions. Dry content of the resulting bean is uniformly low and no burning ing curves for a typical blend of green coffee beans with an or roasting occurs. Beans with high moisture contents in their initial moisture content of 11% are shown in FIG. 7. The center and low moisture contents near the outer edges should drying curve was established on a Model 42200 Wenger Belt not be charged to the roaster until Such equilibration occurs. Dryer under 300 lb. batch conditions. The blend consists of 0194 Green bean drying involves the simultaneous appli equal parts Robusta, natural Arabicas and washed Arabica cation of heat and removal of moisture from the green beans. beans. Preferably, commercial drying is achieved by a con As applied to the second group of embodiments, moisture vective air stream, which enters the drying compartment con removal, i.e. dehydration, can be accomplished by heated air, taining from 0% to 70% moisture at a temperature of from heated Surfaces, microwave, dielectric, radiant or freeze dry about 70° F. to about 325° F., preferably from about 70° F. to ers. These drying operations are described in Fellows, Food about 300° F., more preferably from about 120° F to about Processing Technology, Chapters 14, 17 and 20, incorporated 275° F., and most preferably about 160° F to about 250° F. herein by reference. The preferred drying method is heated air The drying time should be from about 1 minute to about 24 drying; however, inert gases (e.g. helium and nitrogen) can hours, preferably from about 30 minutes to about 24 hours, also be used. Fluidized bed heated air dryers, rotary dryers, more preferably from about 1 hour to about 24 hours, more belt dryers, tray dryers, continuous dryers and conveyor and preferably from about 1 hour to about 12 hours, more prefer convective dryers are particularly preferred; rotary or belt ably from about 1 hour to about 6 hours, and most preferably dryers are most preferred. from about 2 hours to about 6 hours. 0.195 Fluidized bed dryers may be batch or continuous. 0199. In the second group of embodiments, slow drying Continuous fluidized bed dryers can be filled with a vibrating using conventional drying units, like the ones described base to help to advance the beans. Continuous “cascade' above, are easily fitted into existing commercial roasting lines systems, in which the beans are discharged under gravity and are the preferred commercial embodiment. However, from one tray to the next can be used for higher production other drying schemes which achieve the same uniformity of rates. Fluidized bed dryers suitable for use in the second moisture will produce a similar result and are also contem group of embodiments include those manufactured by APV plated by the second group of embodiments. Examples of Crepaco, Inc., Attleboro Falls, Mass.: Bepex Corp., Rolling alternative drying schemes include: vacuum drying; ware Meadows, Ill., Littleford Bros., Inc., Florence, Ky., and Wol house-type drying (i.e. storage in a dehumidified warehouse verine Corporation, Merrimac, Mass. for several months); or pulse drying by heating the beans with 0196. Rotary dryers consist of a slightly inclined rotating one or more short pulses of heat, e.g., 1 sec. to 1 min. at 300° metal cylinder, fitted with internal flights to cause the beans to F-1000° F (149° C.-538°C.), and then allowing the moisture cascade through a stream of hot air as they advance through and temperature within the bean to equilibrate. US 2014/0370181 A1 Dec. 18, 2014
0200. In the second group of embodiments, warehouse 0208. Other fast roast methods useful in producing type drying can be performed in large rooms, warehouse or reduced density coffee are described in U.S. Pat. No. 4.737. storage silos. The coffee may remain in the shipping bag 376 to Brandlein et al., issued Apr. 12, 1988: U.S. Pat. No. provided air is free to flow in and out of the bag (e.g. a coarse 4,169,164 to Hubbard et al., issued Sep. 25, 1979; and U.S. weave burlap bag). Slow drying of this type is typically Pat. No. 4,322,447 to Hubbard, issued Mar. 30, 1982, all of accomplished with air at about 70°F. to about 120° F (about which are herein incorporated by reference. 21°C. to about 49°C.) and a relative humidity of less than 0209 Final roasting according to the second group of 25%. Optionally, a small airflow is distributed throughout the embodiments is characterized by two factors: the color of the drying environment. The time required to achieve desired final roast bean, and the density of the product. moistures is a function of air distribution, air Velocity, air 0210 Roast Bean Color: The coffee beans can be roasted temperature, air relative humidity and the initial moisture to any desired roast color. Darker roasts develop strong fla content of the green beans. Typically, the moisture levels are Vors that are very desirable in many European countries. monitored periodically during the warehouse-type dryer Lighter roasts can be used to produce clear, reddish cup colors period. The drying medium is not limited to air; inert gases with slightly weaker flavors. The Hunter Color “L” scale (e.g. nitrogen and helium) can also be used. system is generally used to define the color of the coffee beans 0201 According to the second group of embodiments, and the degree to which they have been roasted. A complete after the green coffee beans have been uniformly pre-dried technical description of the system can be found in an article and the moisture profile has equilibrated, they are ready for by R. S. Hunter “Photoelectric Color Difference Meter, J. of roasting. The beans should have minimal contact, preferably the Optical Soc. of Amer, 48,985-95 (1958). In general, it is no contact, with moisture to prevent the absorption thereof. noted that Hunter Color “L” scale values are units of light The pre-dried beans should not be allowed to rehydrate to a reflectance measurement, and the higher the value is, the moisture level greater than about 10%, preferably not greater lighter the color is since a lighter colored material reflects than about 7% and most preferably not greater than about 3%. more light. In particular, in the Hunter Color system the “L” It is desirable, but not critical, to charge the beans to the scale contains 100 equal units of division; absolute black is at roaster as soon as possible after pre-drying. the bottom of the scale (L=0) and absolute white is at the top 0202 Roasting of the Dried Beans in the Second Group of (L=100). Thus, in measuring degrees of roast, the lower the Embodiments “L” scale value the greater the degree of roast, since the 0203 The process in the second group of embodiments greater the degree of roast, the darker is the color of the combines the above pre-drying stage with a “fast roaster. roasted bean. These roasters are characterized by their ability to provide an 0211. The roast coffee beans of the second group of expanded roast bean with a whole roast tamped bulk density embodiments have a Hunter L-color of from about 14 to about of from 0.28 to 0.38 gmfcc. 25, preferably from about 17 to about 23. 0204 Fast roasters suitable for use in the second group of 0212 Reduced Density: The roast coffee beans of the sec embodiments can utilize any method of heat transfer. How ond group of embodiments have a whole roast tamped bulk ever, convective heat transfer is preferred, with forced con density of from about 0.27 to about 0.38 g/cc, preferably from vection being most preferred. The convective media can be an about 0.29 to about 0.37 g/cc, more preferably from about inert gas or, preferably, air. Typically, the pre-dried beans are 0.30 to about 0.36 g/cc, and most preferably from about 0.30 charged to a bubbling bed or fluidized bedroaster where a hot to about 0.35 g/cc. air stream is contacted with the bean. Fast roasters operate at inlet air temperature of from about 350° F. to about 1200°F. 0213 Cooling the Roasted Beans in the Second Group of (about 177° C. to about 649° C.) preferably from about 400° Embodiments F. to about 800° F (about 204°C. to about 427°C.), at roast 0214. As soon as the desired roast bean color is reached, times from about 10 seconds to not longer than about 5.5 the beans are removed from the heated gases and promptly minutes, preferably from about 10 to about 47 seconds. cooled by the typically ambient air and/or a water spray. 0205. In a typical batch fast roast, a Thermalo Model 23R Cooling of the beans stops the roast-related pyrolysis reac roaster manufactured by Jabez Burns, is charged with from tions. about 100 to about 300 lbs. (from about 14 to about 136 kg) of 0215 Water spray cooling, also known as “quenching, is dried beans. The beans are roasted for from 1 to about 3 the preferred cooling method in the second group of embodi million Btu/hr (about 293 kW to about 879 kW) and an initial ments. The amount of water sprayed is carefully regulated so preheat temperature of from about 300° F. to about 700°F. that most of the water evaporates off. Therefore, minimal (about 149° C. to about 3.71° C.). water is absorbed by the roasted beans, e.g. typically less than 0206. In a typical continuous fast roast, a Jetzone Model about 6%. 6452 fluidized bed roaster, manufactured by Wolverine 0216 Grinding of the Roasted Beans in Second Group of Corp., is operated with an inlet air temperature of from about Embodiments 500°F. to about 700° F (about 260° C. to about 3.71° C.) and 0217. After the roast coffee beans have been cooled a residence time of from 15 to about 60 sec at typical burner according to the second group of embodiments, they can be rates of about 2.4 MM Btu/hr (about 703 kW). prepared for brewing. Coffee brewing is achieved by perco 0207 Roasting equipment and method suitable for roast lation, infusion or decoction. During a brewing operation, ing coffee beans according to the second group of embodi most coffee solubles and Volatiles are extracted into an aque ments are described, for example, in Sivetz, Coffee Technol ous medium. This extraction is made more efficient by break ogy, Avi Publishing Company, Westport, Conn. 1979, pp. ing down the whole bean into Smaller pieces. This process is 226-246, herein incorporated by reference. See also U.S. Pat. generally referred to as "grinding.” Preferred grinding tech No.3,964,175 to Sivetz, issued Jun. 22, 1976, which discloses niques result in an average particle size of from about 300 to a method for fluidized bed roasting of coffee beans. about 3000 microns. US 2014/0370181 A1 Dec. 18, 2014
0218 Particle size also impacts the brew strength of cof 0230 Increased Flavor Strength: The brew flavor strength fees prepared from different brewing apparatus. Automatic of the coffees produced by the second group of embodiments Drip coffee grinds typically have an average particle size of is typically greater than that produced by prior 16-ounce about 900 um and percolator grinds are typically from about coffee blends, and even fast roast non-dried reduced density 1500 um to about 2200 um. coffee blends. 0219 Descriptions of grinding operations suitable for use 0231 Roast Time Reduction: Reduced roast bean densi in the second group of embodiments are described in Sivetz, ties are achieved under the roast conditions described above supra. pp. 265-276, herein incorporated by reference. in from about 10 seconds to about 30 minutes, preferably 0220. The roast and ground coffee beans of the second from about 10 seconds to about 5.5 minutes, most preferably group of embodiments have a ground tamped bulk density of about 10 to about 47 seconds. It has been observed that the from about 0.25 to about 0.39 gm/cc, preferably from about roasting times of the second group of embodiments are about 0.28 to about 0.36 gm/cc, and most preferably from about 2/3 those observed when no pre-drying is utilized. 0.28 to about 0.34 gmfcc. 0232 Preferred Coffee Varieties in Second Group of 0221 Flaking of the Resulting Ground & Roast Coffee in Embodiments the Second Group of Embodiments 0233. It has been observed that the process of the second 0222 Flaked coffees may have improved characteristics. group of embodiments is Suitable for roasting all varieties of Flaked coffee is described in U.S. Pat. No. 4331,696; U.S. coffee. However, the flavor character of certain coffee is Pat. No. 4,267,200; U.S. Pat. No. 4,110,485; U.S. Pat. No. actually improved by the claimed process. “Milds' and 3,660,106; U.S. Pat. No. 3,652,293; and U.S. Pat. No. 3,615, washed arabicas show a slight improvement, while Brazilians 667, of which are herein incorporated by reference. and other natural Arabicas show more improvement. Robus 0223 Flaked roast & ground products of the second group tas are improved the most and have a noticeably less harsh of embodiments are desirable. Preferred flaked products are flavor. Accordingly, Brazilians, natural Arabicas, washed produced by grinding the roast coffee to an average particle Arabicas and Robustas are preferred beans for use in the size from about 300 to about 3000 um, normalizing the second group of embodiments. Robustas being the most pre ground product, and then milling the coffee to a flake thick ferred. ness of from about 2 to about 40 thousandths of an inch (about 0234. The blending of beans of several varieties, before 51 to about 1016 um), preferably from about 10 to about 30 and after roasting or pre-drying, is also contemplated by the (about 254 to about 762 um), most preferably from about 20 second group of embodiments. Likewise, the processing of to about 24 (about 508 to about 610 um). decaffeinated or partially decaffeinated coffee beans are also 0224 Characteristics of the Roasted Products in the Sec contemplated by the second group of embodiments. ond Group of Embodiments 0225. The benefits of the second group of embodiments Analytical Methods in the Second Group of Embodiments are observed by “fast roasting the beans to produce a reduced density roast bean. Surprisingly, it has been discovered that I. Whole Roast Tamped Bulk Density Determination when green beans are pre-dried prior to roasting according to 0235. This method specifies the procedure for determining the second group of embodiments, the resulting roasted beans the degree of puffing that occurs in the roasting of green exhibit the following characteristics: coffee. This method is applicable to both decaffeinated and 0226. More Uniform Roasting: The roasted beans pro non-decaffeinated whole roasts. duced according to the second group of embodiments show a high degree of roast uniformity when compared to non-dried Apparatus beans roasted in a similar manner. 0236 Weighing container: 1,000 ml stainless steel beaker 0227 Less Bean to Bean Color Variation: Bean-to-bean or equivalent color variation within the roast is an indication of uniformity 0237 Measuring container: 1,000 ml plastic graduated of roast. Color variations within the bean are also another cylinder, 5 ml graduations indicator of roast uniformity. Both are important to the aes thetic appeal of the coffee to the consumer. 0238 Scale: 0.1 gm sensitivity 0228. The Hunter L-scale system is employed in the sec 0239 Vibrator: Syntron Vibrating Jogger; Model J-1 or ond group of embodiments to establish uniformity of roast equivalent. Syntron Company—Homer City, Pa. within the bean. Hunter L-color of the roast bean is normally 0240 Funnel: Plastic funnel with tip cut off to about 1" lower than that of the ground product. The reason for this outlet effect is that the exterior of the roast bean is roasted to a 0241 Automatic Timer: Electric, Dimco-Gray; Model greater degree (i.e. darker) than the interior of the bean. As No. 171 or equivalent used herein, the term Hunter AL-color relates to this increase in the Hunter L-color of roast beans when compared after and Operation before grinding and is defined as follows: 0242 Weigh 200 grams of whole bean coffee to be tested Hunter AL Lane-Libefore into beaker. Place the graduated cylinder on the vibrator. Using the funnel, pour the coffee sample into the cylinder. where, Level the coffee by gently tapping the side of the cylinder. La Hunter L-color of the whole roast bean; and Vibrate 30 seconds at No. 8 setting. Read volume to nearest 5 L. Hunter L-color of the ground roast bean. ml. 0229 Hunter AL-color values for roast and ground coffee 0243 Tamped density can be determined by dividing the according to the second group of embodiments are less than weight of the coffee by the volume occupied (after vibrating) about 1.2, preferably less than about 0.6. in the graduated cylinder. US 2014/0370181 A1 Dec. 18, 2014 13
Cracking breaks the beans into very large pieces and releases Weight of Coffee (gms) the chaffDuring the grinding step the pieces of ground coffee Tamped Density = Volume of Coffee (cm3) and chaff are broken into smaller pieces. Since the surface area increases, more of the naturally occurring coffee oil is 0244. For standardizing the measurements between differ exposed. The normalizer is a mixing chamber with rotating ent coffees, all density measurements herein are on a 4.5% paddles which beat the light-colored chaff into tiny fragments adjusted moisture basis. For example, 200 grams of whole and mix them with the dark-colored coffee oil. Normalization bean coffee having a 2% moisture content would contain 196 gives the coffee a better appearance because the Small, dark grams of dry coffee and 4 grams of water. If the Volume was ened chaff particles are more difficult to see against the back 600 ccs, the unadjusted density would be 200 gms/600 ground of the ground coffee beans. ccs=0.33 gmfcc. On a 4.5% adjusted moisture basis, the 0258. In the third group of embodiments according to the calculation is: 4.5%x200 gms=9 gms water. To make the present invention, the coffee composition 110/130 and bev density calculation on an adjusted moisture basis, take 196 erage material 120 as shown in FIGS. 1A, 1B, and 1C com gms dry coffee--9 gms water 205 gms total. Adjusted den prises a reduced density roast and ground coffee product, sity=205 gms/600 ccs=0.34gmfcc. which is produced by a process comprising the steps of: (a) cracking roasted coffee beans to a size such that about 40% to II. Ground Tamped Bulk Density Determination about 80% are retained in a 6-mesh screen (3.36 mm, 0.132 in.); then (b) normalizing the cracked beans; and then (c) 0245. This method is applicable to ground or flaked prod grinding the cracked and normalized beans. The roast and uct. ground coffee product produced by the combination of the three steps has a density between about 0.24 g/cc and about Apparatus 0.41 g/cc. The reduced density roast and ground coffee prod 0246 Weighing container: 1,000 ml glass beaker or uct has an acceptable non-chaffy or less chaffy appearance. equivalent Problems associated with the use of an air removal step or 0247 Measuring container: 1,000 ml plastic graduated screening step are avoided. cylinder, 10 ml graduations 0259. In connection to the background of the third group 0248 Scale: 0.1 gm or 0.01 ounce sensitivity of embodiments, normalization has the additional effect of 0249 Vibrator: Syntron Vibrating Jogger-Model J-1A (or densifying the coffee because the mixing rounds off the edges equivalent). Syntron Company-Homer City, Pa. (Calibrated of the coffee particles, allowing them to pack closer and more by Factory analytical Services) efficiently together. This densifying effect of normalization is (0250) Funnel: Plastic funnel with tip cut off to about 1" a problem if one wishes to produce a lower density coffee outlet hole. product. An air removal step or screening step can be used 0251 Automatic timer (optional): automatic timer-auto instead of normalization to deal with the chaff problem; how matic shutoff and reset. ever, with air removal the small coffee particles are lost with 0252 Calibration device: Amplitude Meter and Trans the chaff, and with screening the small pieces of chaffare not ducer Mod. AM-100, Power Time Control, Indiana, Pa. removed. These alternatives to normalization are thus imper 0253 Calibration of Syntron Vibrating Jogger fect solutions to the chaff problem. 0254 An amplitude of 0.035 inches results in consistent 0260 U.S. Pat. No. 4,349,573 to Stefanucci et al., issued density measurements with little product break-up when Sep. 14, 1982, discloses a process for making a low density using the 300 gram density method. coffee. The process comprises: (a) preparing a roasted high quality coffee bean fraction under short roasting conditions Operation effective to produce a roasted high quality coffee bean frac 0255 Weigh 300 grams of coffee to be measured into the tion having a roast color of no more than 50 and a bulk density beaker. Place the graduate cylinder on the vibrator table. Pour less than 0.35 g/cc; (b) preparing a roasted intermediate qual the coffee through the funnel into the graduate cylinder. Level ity coffee bean fraction under short roasting conditions effec the coffee by gently tapping the side of the cylinder. Vibrate tive to produce a roasted intermediate quality coffee bean for one minute. Read volume. Calculation fraction having a roast color of 60 and a bulk density less than 0.32 g/cc; (c) preparing a roasted low quality coffee bean fraction under short roasting conditions effective to produce a 300 gn roasted low quality coffee bean fraction having a roast color Tamped Density in gmfcm3 = Volume of coffee in ml of 85 and a bulk density less than 0.40 g/cc; (d) blending the roasted fractions of steps (a), (b) and (c) in a ratio effective to produce a ground blend having a maximum free flow density 0256 The density measurements used herein are calcu of 0.30 g/cc and wherein the high quality coffee constitutes lated on a 4.5% adjusted moisture basis, as described in the 25-40%, the intermediate quality coffee constitutes 50-60% previous section. and the low quality coffee constitutes 10-15% of the final blend; (e) grinding the roasted blend of step (d), while bypass Roasting and Grinding ing the grinder normalizer, to an average particle size of 0257 The coffee ingredient contained in the coffee com 880-900 microns for electric percolator grind; of 830-850 position 110/130 and beverage material 120 as shown in microns for stove percolator grind; or of 740-760 microns for FIGS. 1A, 1B, and 1C may be independently from each other automatic drip grind. produced from any Suitable roasting and grinding process, 0261. In the Stefanucci et al. process the ground beans are including those described above. For example, roasted coffee not normalized. While this process produces a low density beans may be cracked, then ground, and then normalized. coffee, the low density is achieved by avoiding the normal US 2014/0370181 A1 Dec. 18, 2014 ization step altogether. This results in a chaffy appearance in bution of this development is the discovery that grinding the ground product. The chaff must then be removed using air coarse, already normalized coffee particles results in a low or screens (with their inherent problems discussed above), or density product with acceptable appearance. it can be left in the coffee, creating an unacceptable appear 0271 The term “density” as used in third group of aCC. embodiments refers to tamped bulk density, the overall den 0262 The third group of embodiments provides a process sity of a plurality of particles measured after vibratory settle of making a reduced density roast and ground coffee in which ment in a manner such as that described on page 529 of Sivetz the chaff problem is addressed by a method other than by et al., “Coffee Technology”. Avi Publishing Company, West eliminating the normalization step. In other words, it provides port, Conn. (1979). a process which retains the normalization step but still pro 0272. The process of the third group of embodiments duces a low density coffee. The third group of embodiments works with any starting blend of green coffee beans. The three therefore produces a reduced density roast and ground coffee major types of coffee beans are milds, Brazilians, and Robus having a non-chaffy appearance. tas. Botanically, the milds and Brazilians are traditionally 0263. One aspect of the third group of embodiments pro thought of as Arabicas. vides for a coffee composition for use in a beverage unit and 0273. The milds give coffee brews which are fragrant and method thereofas defined in the Summary of the Invention, acidic. Brazilian beans result in coffee brews which are rela wherein the coffee composition comprises a reduced density tively neutral flavored. The Robusta beans produce brews roast and ground coffee product made from a process com with Strong distinctive flavors that possess varying degrees of prising the steps of: (a) cracking roasted coffee beans to a size dirty or rubbery notes. Traditionally, the milds are the most such that about 40% to about 80% are retained on a 6-mesh expensive of the three types ofbeans, with Brazilians being of screen; then (b) normalizing the cracked beans; and then (c) intermediate expense, and Robustas being least expensive. grinding the cracked and normalized beans; the coffee prod 0274 Decaffeinated beans can be used in this process as uct produced having a density between about 0.24 g/cc and well. Any standard decaffeination process is acceptable. about 0.41 g/cc. 0275 Any of the variety of roasting techniques known to 0264. In more specific examples under this aspect, the the art can be used to roast the green coffee in the process of coffee beans may be cracked to a size such that about 50% to the third group of embodiments. In the normal operation of about 80% (e.g. about 60% to about 80%) are retained on a preparing conventional roast and ground coffee, coffee beans 6-mesh screen. are roasted in a hot gas medium at a temperature of from about 0265. The third group of embodiments will be further 176.7°C. (350°F) to about 260° C. (500°F) with the time of described in the following, and exemplified by Examples roasting being dependent on the flavor characteristics desired 10-12. in the coffee beverage when brewed. Where coffee beans are 0266. In third group of embodiments, by changing the roasted in a batch process, the batch roasting time at the normal coffee grinding procedures, the normalization step hereinbefore given temperatures is generally from about 2 can be retained to deal with the chaff problem, while at the minutes to about 20 minutes. Where coffee beans are roasted same time a low density coffee can be produced. in a continuous process, the residence time of the coffee beans 0267 Conventional commercial grinding equipment is in the roaster is typically from about 30 seconds to about 9 built so that cracking rolls are first in the order, followed by minutes. The roasting procedure can involve static bed roast grinding rolls and then a normalizer. In the original equip ing as well as fluidized bed roasting. ment design of a normalizer, two necessary functions were 0276. In the third group of embodiments, the coffee beans performed: making the appearance of the coffee more uni can be roasted to any desired roast color. Darker roasts form and acceptable, and increasing the density of the coffee develop strong flavors that are very desirable in many Euro to fit into the appropriate container. When the need for a pean countries. Lighter roasts can be used to produce clear, reduced density coffee product arose, the only obvious solu reddish cup colors with slightly weaker flavors. The Hunter tion was to reduce or eliminate the normalizing step to lower Color “L” scale system is generally used to define the color of density. the coffee beans and the degree to which they have been 0268. The unobvious solution, and a key to the third group roasted. A complete technical description of the system can of embodiments, was the discovery that the dual goals of be found in an article by R. S. Hunter, “Photoelectric Color reduced density and acceptable appearance can be achieved Difference Meter, J. of the Optical Soc. of Amer, 48,985-95 by reversing the order of the normalization and grinding (1958). In general, it is noted that Hunter Color “L” scale steps. It was found that grinding coarse, already normalized values are units of light reflectance measurement, and the coffee particles results in a low density product with an higher the value is, the lighter the color is since a lighter acceptable non-chaffy appearance. colored material reflects more light. In particular, in the 0269. In the process of the third group of embodiments, Hunter Color system the “L” scale contains 100 equal units of coffee beans are first cracked into very large pieces having a division; absolute black is at the bottom of the scale (L=0) and specific size, thereby releasing the chaff. If the beans are absolute white is at the top (L=100). Thus, in measuring cracked too coarse, the final product will be chaffy, and if the degrees of roast, the lower the “L” scale value the greater the beans are cracked too fine, the final product will be too dense. degree of roast, since the greater the degree of roast, the 0270. The coffee is then normalized to color and break up darker is the color of the roasted bean. the chaff. The density of the coffee is increased at this point 0277. Typical roasting equipment and methods for roast because the edges of the large coffee particles have been ing coffee beans are described, for example, in Sivetz & rounded off. However, these large particles are then ground Desrosier, Coffee Technology, Avi Publishing Company, into Smaller particles by passing them through grinding rolls. Westport, Conn., 1979, pp. 226-246. U.S. Pat. No. 3,964,175 The grinding creates irregular edges again, and the coffee has to Sivetz, issued Jun. 22, 1976, discloses a method for fluid a low density without a chaffy appearance. A unique contri ized bed roasting of coffee beans. US 2014/0370181 A1 Dec. 18, 2014
0278. In the process of the third group of embodiments, cially true if the coffee particles will be mixed after the the roasted coffee beans are first cracked to a size such that normalization operation, for example, in a screw conveyor. about 40% to about 80% are retained on a 6-mesh U.S. Stan This mixing is in effect added normalization, so the normal dard Screen. Preferably, they will be cracked to a size of about ization step may need to be shortened to compensate for this 50% to about 80% on a 6-mesh U.S. Standard Screen, and added handling. In general, the normalization may take most preferably to a size of about 60% to about 80% on the between about 15 seconds and about 1 minute, depending on 6-mesh screen. U.S. Standard Screens can be related to par the type of equipment used and the feed rate. ticle size. See Perry et al., “Perry's Chemical Engineers 0285. The coffee particles are sufficiently normalized or Handbook”, 6th Ed., p. 21-15, McGraw-Hill Book Co., New mixed when the light-colored large pieces of chaffare turned York, N.Y. (1984). A 6-mesh screen has an opening of 3.36 into dark-colored (because of the coffee oil) small pieces of mm. or 0.132 inches. This means that from about 40% to chaff that are difficult to see against the background of the about 80% of the particles are larger than about 3.36 mm, and coffee. about 20% to about 60% are smaller. 0286 The type of normalization equipment used is not 0279. The cracking operation cracks the beans to as coarse critical for the third group of embodiments. The normalizer is a size as possible with substantially all of the beans cracked, essentially just a mixer. Examples of suitable equipment area and with substantially all of the beans having their chaff Gump normalizer or a ribbon blender. The equipment can be loosened. It has been found that these conditions are met modified (especially in length) for optimum industrial use. when about 40% to about 80% of the cracked beans are 0287. In the last step of the present process in the third retained on a 6-mesh screen. group of embodiments, the cracked and normalized beans are 0280. If more than about 80% of the cracked beans remain ground to the desired size. The process will work with any on a 6-mesh screen, the cracked beans are too coarse and not type of grind. The standard grinds (from coarsest to finest) are all of the chaff is loosened, and the final product has an electric perk, regular, automatic drip coffee, drip, and fine. appearance that is too chaffy. If less than about 40% of the For example, automatic drip coffee has a particle size distri cracked beans remain on the 6-mesh screen, the beans are bution of about 7% above a 14-mesh screen, about 18% above cracked too finely, and the final product is too dense. a 16-mesh screen, and about 50% above a 20-mesh screen, 0281 Any comminution equipment can be used for the while regular coffee has a particle size distribution of about cracking operation of this process. For example, a Gump 32% above a 14-mesh screen, about 42% above a 16-mesh grinder, manufactured by B. F. Gump Company, Chicago, Ill., screen, and about 70% above a 20-mesh screen. Grinding of contains both cracking and grinding rolls, and it is suitable for the coffee can be done in any of the ways known to those the practice of the third group of embodiments. The present skilled in the art. process is not equipment specific. Any grinder with cracking 0288 The roast and ground coffee product produced by rolls or any other type of comminution equipment or methods the combination of the cracking, normalizing and grinding can be used as long as they are capable of cracking the beans steps of the third group of embodiments must have a density to the desired size. between about 0.24 g/cc and about 0.41 g/cc. This density 0282. Some different equipment and methods for crack range is determined primarily by the need for a reduced ing, normalizing, and grinding coffee are found in Sivetz et density coffee, by the physical fit of the coffee product into al., Coffee Technology, Avi Publishing Company, Inc., West the coffee container, and by the amount of coffee used to brew port, Conn., pp. 265-276 (1979). Commercially sold equip the coffee drink. ment (for example, Gump) which combines apparatus for 0289. The final product density is controlled mostly by the cracking, grinding, and then normalizing has the three opera cracking and normalizing steps as explained above, and by tions in that order. Therefore, this commercial equipment will the degree of roast, with a darker roast generally producing a have to be changed to put the normalizing step before the less dense coffee bean. The grinding step has little effect on grinding step. the product density, according to the third group of embodi 0283. In the third group of embodiments, it does not matter mentS. how many cracking rolls or grinding rolls are used in the cracking and grinding steps, or whether other comminution Post-Grinding Treatment: Flavoring equipment is used for the cracking and grinding, as long as the 0290. In preparing the coffee composition for use in a coffee is cracked to the correct particle size range and ground beverage unit as defined in the Summary of the Invention, the to the desired size. coffee in the coffee composition 110/130 and beverage mate 0284. After cracking, the beans are normalized. In the rial 120 as shown in FIGS. 1A, 1B, and 1C may result from normalization process the cracked coffee particles are heavily any suitable flavoring treatment, before, during and/or after mixed together. This causes the chaff to break into smaller the roasting and/or grinding step(s). In the fourth group of pieces and coffee oil to be released from the coffee particles. embodiments according to the present invention, non-segre The smaller chaff particles mixed with the coffee oil are then gating, non-agglomerated flavored coffee compositions are less conspicuous against the background of the coffee par provided. In particular, the fourth group of embodiments ticles. The oil is also absorbed into the chaff and is not lost. relates to novel flavored coffee compositions that minimize or There it can provide aroma to the ground coffee and addi inhibit the segregation and separation of constituent compo tional flavors during processing. In the process of the third nents, and the corresponding processes for making Such com group of embodiments, the ideal normalization procedure is positions. The flavored coffee compositions herein are char to normalize the cracked coffee particles just enough to acterized as having a roast and ground, an instant coffee adequately change the appearance of the chaff, and then stop component, or mixtures thereof. The roast and ground coffee normalizing. Too much normalization will densify the coffee component will have a moisture level in the range of from particles to an unacceptable extent. It is better to err on the about 1% to about 15%, a particle density in the range of from side of leaving a small amount of chaff visible. This is espe about 0.1 g/cc to about 0.45 g/cc, and a mean particle size US 2014/0370181 A1 Dec. 18, 2014
distribution in the range of from about 400 microns to about ing in inconsistent product quality in the ready to drink form 1300 microns. The instant coffee components used herein of the beverage, as some prepared beverage portions will will have a particle density in the range of from about 0.1 g/cc receive more or less than the intended flavor level. to about 0.8 g/cc, a mean particle size distribution in the range 0296 Yet another approach to providing flavored coffee of from about 250 microns to about 2360 microns, and a products is the practice of separating the flavor and coffee moisture level in the range of from about 1% to about 4.5%. ingredients by combining the flavoring ingredient with a filter The flavored coffee composition further includes a flavoring media or other membrane that the extracted or solubilized component with a moisture level in the range of from about coffee solution must come into contact with. See U.S. Pat. No. 1% to about 7%, a particle density in the range of from about 6,004,593 to Soughan et al., which is herein incorporated by 0.1 g/cc to about 0.8 g/cc, and a mean particle size distribution reference. This process, however, requires the use of special in the range of from about 5 microns to about 150 microns. equipment and/or materials (e.g., filters) to obtain a flavored The ratio of coffee component particle size to flavor compo coffee beverage product. Moreover, not all consumers desired nent particle size is in the range of from about 100:1 to about flavors may be available in a form capable of being utilized in 5:1. Such a fashion. 0291. In connection to the background of the fourth group 0297. Therefore, considerable effort has been expended in of embodiments, flavored coffee beverage products enjoy an attempt to address the product formulation and consumer considerable popularity and make up an increasingly signifi acceptance limitations of using the flavored compositions and cant proportion of daily consumed beverages. However, these techniques heretofore described. Furthermore, there remains flavored coffee beverages are complicated and expensive to a need in the art for compositions and methods of flavoring produce and frequently suffer from inconsistent product qual coffee that ensure high quality and consistent flavor delivery. ity; one such reason is the way in which these coffee bever In particular, inexpensive non-segregating flavoring methods ages are flavored. that are easily adaptable to a variety of coffee materials are 0292. One common approach to producing flavored coffee desirable. Accordingly, it is an object of the fourth group of beverage products is the admixing of a dry coffee compound embodiments to provide coffee compositions and methods with a dried, agglomerated flavoring ingredient of similar size which address these needs and provide further related advan capable of solubilization when the coffee product is being tages. extracted and/or dissolved. The flavoring ingredients are bound together via the application of an agglomerating fluid 0298. The fourth group of embodiments is directed or binding solution. As there is little or no difference in towards methods of flavoring coffee, and the products and relative particle sizes between the coffee particles and the compositions derived therefrom, that minimize both process flavoring ingredients, segregation and separation generally ing steps and cost while simultaneously ensuring a coffee product with a consist and uniform flavor impact. In particu do not occur. See U.S. Pat. No. 6,207,206 B1 to Mickowski et lar, the fourth group of embodiments relates to novel flavored al., herein incorporated by reference. coffee compositions that minimize or inhibit the segregation 0293. However, this approach has several deficiencies, and separation of constituent components, and the corre most notable of which is the increased production cost result sponding processes for making Such compositions. The fla ing from both additional raw materials and additional pro Vored coffee compositions herein comprise, on a dry weight cessing steps required to produce the agglomerates. More basis, from about 80% to about 99.5% of a coffee component, over, inconsistent flavor delivery is frequently encountered, preferably from about 85% to about 98%, more preferably resulting from differing rates of extraction and/or solubiliza from about 90% to about 97%, and yet more preferably from tion between the coffee and the agglomerated flavoring ingre about 92% to about 96%. dients. 0294. In an attempt to overcome the deficiencies of the 0299 The coffee component in fourth group of embodi agglomeration flavoring method, liquid flavoring compo ments is comprised of a roast and ground coffee component, nents have been used to deliver a desired degree of flavoring an instant coffee component, or mixtures thereof. The roast impact. In this approach, liquid flavoring ingredients are and ground coffee component will have a moisture level in the applied to the Surface of coffee particles so as to coat them. range of from about 1% to about 15%, a particle density in the However, this approach is not without its own set of problems. range of from about 0.1 g/cc to about 0.45 g/cc, and a mean The liquid flavoring compounds typically used in these appli particle size distribution in the range of from about 400 cations contain Volatile compounds that may evaporate when microns to about 1300 microns. The instant coffee compo exposed to the atmosphere, thereby losing their potency. nents used herein will have a particle density in the range of Additionally, not all flavor combinations are possible, as a from about 0.1 g/cc to about 0.8 g/cc, a mean particle size desired flavor may not be available in liquid form. Finally, distribution in the range of from about 250 microns to about liquid flavoring compositions frequently contain evaporative 2360 microns, and a moisture level in the range of from about solvents that contribute to volatile flavor loss. These solvents 1% to about 4.5%. also tend to undergo adverse reactions with the materials (0300. The flavored coffee composition herein further typically used in conventional coffee containers (e.g., tin, comprises, on a dry weight basis, from about 0.5% to about plastic, paper, and the like). The use of specially treated and 20% of a flavoring component, preferably from about 2% to costly packaging is therefore required in order to resist Such about 15%, more preferably from about 3% to about 10%, yet reactions and preserve coffee flavor, quality, and aroma. more preferably from about 4% to about 8%. 0295) To compensate for evaporation it is necessary to 0301 The flavoring component in fourth group of apply the flavoring agent in amounts well in excess of what is embodiments has a moisture level in the range of from about actually required to deliver the desired flavor load. Another 1% to about 7%, a particle density in the range of from about shortcoming of the application of liquid flavorants is the 0.1 g/cc to about 0.8 g/cc, and a mean particle size distribution non-uniform coverage of the coffee particles, thereby result in the range of from about 5 microns to about 150 microns. US 2014/0370181 A1 Dec. 18, 2014
The ratio of coffee component particle size to flavor compo sented as 0%. RSD. The Distribution Value is calculated nent particle size is in the range of from about 100:1 to about according to the “Distribution Value Determination method 5:1. explained herein. 0302 As such, one aspect of the fourth group of embodi 0314. The term 'Agglomeration' is defined as the process ments provides for a coffee composition for use in a beverage of preparing relatively larger particles by combining a num unit Such as a cartridge and method thereofas defined in the ber of relatively smaller particles into a single unit. Many Summary of the Invention, wherein the coffee composition specialized processes and types of processing equipment comprises a non-agglomerated flavored coffee composition have been developed for the agglomeration of particulate made by a method comprising the steps of solids. See, for example, pp. 177-209 of Coffee Solubilization 0303 a) combining: Commercial Processes and Techniques, Pintaufo, N. D., (0304 (i) from about 80% to about 99.9% of a coffee Noyes Data Corporation, 'Agglomeration Techniques'. component, wherein said coffee component has a mois (1975), herein incorporated by reference. ture level in the range of from about 1% to about 5%, a 0315. It will be appreciated by the ordinarily skilled arti particle density in the range of from about 0.28 g/cc to san that the following basic operating principles are involved about 0.33 g/cc, a mean particle size distribution in the in practically all agglomeration techniques. First, an agglom range of from about 650 microns to about 800 microns; erating fluid (e.g., oil, liquid water or steam) is dispersed and throughout the particles to be agglomerated, causing part or (0305 (ii) from about 0.1% to about 20% of a flavoring all of the surfaces of the particles to become tacky. Subse component, wherein said flavor component has a mois quently, the particles are agitated, allowing the tacky Surfaces ture level in the range of from about 1% to about 4%, a of the particles to come into contact with and adhere to other particle density in the range of from about 0.4 g/cc to particles. Proper control of the amount of agglomerating fluid and the type and time of agitation will provide control over the about 0.5 g/cc, a mean particle size distribution in the final size of the agglomerated product. Agglomeration meth range of from about 40 microns to about 50 microns; ods which use water as an agglomerating fluid typically result 0306 wherein the size ratio of said coffee component to in a high density product which does not quickly dissolve. said flavor component is in the range of from about Following agglomeration and agitation, the resulting agglom 100:1 to about 5:1; erated particles are dried, typically to a moisture content of 0307 b) mixing said coffee component and said flavoring about 3.5% or less. It is believed in the art that this moisture component for a period of time sufficient for said flavored level will help minimize flavor deterioration and caking. The coffee composition to exhibit a Distribution Value of less than agglomerated particles can be air dried, vacuum dried, dried about 20% RSD: in a fluidized bed, dried in a vibratory fluidized bed, or with 0308 wherein said coffee component is selected from the any other Suitable drying apparatus. group consisting of roast and ground coffee, instant coffee, 0316 Publications and patents are referred to throughout and mixtures thereof; the fourth group of embodiments. All references cited in the 0309 wherein said flavoring component is selected from fourth group of embodiments are hereby incorporated by the group consisting of dried flavoring compounds, crystal reference. All percentages and ratios are calculated by weight line flavor compounds, encapsulated flavoring compounds, in the fourth group of embodiments unless otherwise indi encapsulated liquid flavoring compounds, and mixtures cated. All percentages and ratios, unless otherwise indicated, thereof, and are calculated based on the total composition. 0310 further comprising one or more additional ingredi 0317. As used in the fourth group of embodiments, and ents selected from the group consisting of creamers, aroma unless otherwise indicated, the use of a numeric range to enhancers, natural Sweeteners, artificial Sweeteners, thicken indicate the value of a given variable is not intended to be ing agents, and mixtures thereof. limited to just that stated range. One of ordinary skill in the art 0311. The fourth group of embodiments as described will appreciate that the use of a numeric range to indicate the above will be further described in the following, and exem value of a variable is meant to include not just the values plified by Examples 13-17. bounding the stated range, but also all values and Sub-ranges contained therein. By way of example, consider variable X A. Definitions in the Fourth Group of Embodiments which is disclosed as having a value in the range of 1 to 5. One of ordinary skill in the art will understand that variable X is 0312. The term “Bulk Density” refers to the overall den meant to include all integer and non-integer values bounded sity of a plurality of particles measured in the manner by the stated range. Moreover, one of ordinary skill in the art described on pp. 127-131 of Coffee Processing Technology, will appreciate that the value of the variable also includes all Vol. II, Avi Publishing Company, Westport, Conn. (1963), combinations and/or permutations of sub-ranges bounded by herein incorporated by reference. As used herein, the term the integer and non-integer values, unless otherwise indi “PSD means particle size distribution as defined on pp. cated. 137-140 of Coffee Processing Technology, Vol. II, Avi Pub 0318 All component or composition levels are in refer lishing Company, Westport, Conn. (1963), herein incorpo ence to the active level of that component or composition and rated by reference. are exclusive of impurities, for example, residual solvents or 0313. The term “Distribution Value' is defined as the by-products, which may be present in commercially available numerical representation of the degree to which the flavoring SOUCS. components are distributed throughout the flavored coffee 0319 Referred to herein are trade names for components compositions, or portions thereof. The value is represented as including various ingredients utilized in the fourth group of a distribution value percentage relative standard deviation embodiments. The inventors herein do not intend to be lim (DV% RSD), where a uniform distribution would be repre ited by materials under a certain trade name. Equivalent mate US 2014/0370181 A1 Dec. 18, 2014 rials (e.g., those obtained from a different source under a defined in terms of readings measured on a Hunter colorim different name or catalog number) to those referenced to by eterand specifically the values L*, a and b* derived from the trade name may be substituted and utilized in the composi Hunter CIE scale. See pages 985-95 of R. S. Hunter, “Photo tions, kits, and methods described herein. electric Color Difference Meter.” J. of the Optical Soc. of 0320 In the description of the fourth group of embodi Amer. Volume 48, (1958). The beans are then cooled to stop ments, various embodiments and/or individual features are roast-related pyrolysis reactions. The beans are then prepared disclosed. As will be apparent to the ordinarily skilled prac for brewing or extracting, either on site or by the ultimate titioner, all combinations of such embodiments and features consumer, by grinding. Preferred grinding techniques for pre are possible and can result in preferred executions of the paring the roast and ground coffees to be used herein will fourth group of embodiments. result in mean particle size distributions in the range of from about 400 microns to about 1300 microns, preferably in the B. Ingredients in the Fourth Group of Embodiments range from about 450 microns to about 1000 microns, more preferably in the range from about 650 microns to about 800 0321) The non-agglomerated, flavored coffee composi microns. tions in the fourth group of embodiments comprise a coffee 0326. As used herein, roast and ground coffee also refers component and a flavoring component that are in intimate to "flaked' coffees. Flaked coffee is described in U.S. Pat. contact with each other. The flavoring and coffee components Nos. 4.331,696; 4,267,200; 4,110,485;3,660,106;3,652,293; remain in contact with each other in the absence of a binding and 3,615,667, each of which is herein incorporated by ref agent and/or agglomerating solution. eeCe. 0327. The roast and ground coffee component used herein 1. Coffee Component will have a particle density in the range of from about 0.1 g/cc 0322 The coffee component of the fourth group of to about 0.45 g/cc, preferably in the range from about 0.25 embodiments is comprised of roast and ground coffee par g/cc to about 0.4 g/cc, more preferably in the range from ticles, instant coffee particles, or mixtures thereof. The roast about 0.28 g/cc to about 0.33 g/cc. Moreover, the roast and and ground coffee utilized herein is commonly known in the ground coffee components used herein, will have a moisture art, and is a widely utilized form of coffee. A variety of level in the range of from about 1% to about 15%, preferably processes are known to those skilled in the art for roasting, from about 1% to about 10%, more preferably from about 1% grinding or otherwise preparing coffee. The roasting condi to about 7%, even more preferably from about 1% to about tions selected for a given coffee source can be characterized 5%. by roast time, roasting equipment, and a Hunter L* color. 0328. The coffee component of the fourth group of 0323) Typically, roast and ground coffee is prepared by embodiments may also be comprised of instant coffee, either drying green coffee beans, roasting the beans, cooling the alone or in combination with a roast and ground coffee. The roasted beans, and subsequently grinding the beans, though instant coffee utilized herein is of the type commonly known those skilled in the art will appreciate that the exact sequence in the art. Suitable instant coffees for use herein can be pre may vary somewhat. See, for example, U.S. Pat. No. 4,637, pared from any single variety of coffee or a blend of different 935, to Kirkpatricket al., issued Jan. 20, 1987, herein incor Varieties. The instant coffee can be caffeinated, decaffeinated, porated by reference, which describes a unique process for orablend of both and can be processed to reflect a particularly preparing a roast and ground coffee, and also discusses other desirable flavor characteristic such as espresso, French roast, known processes for preparing roast and ground coffee. or the like. 0324. The beans utilized in making the flavored coffee 0329. An instant coffee component of the type used in the compositions of the fourth group of embodiments may be any fourth group of embodiments can be prepared by any conve of a variety of available coffee beans, or a blend of two or nient processes, a variety of which are known to those skilled more varieties. For example, Brazilian, natural Arabica, in the art. Typically, instant coffee is prepared by roasting and washed Arabica, and Robusta varieties may be used, either grinding a blend of coffee beans, extracting the roast and alone or in combination. The roast and ground coffee can be ground coffee with water to form an aqueous coffee extract, caffeinated, decaffeinated, or a blend of both. The coffee may and drying the extract to form instant coffee. Instant coffee also be processed to reflect one of many unique flavor char useful in the fourth group of embodiments is typically acteristic such as espresso, French roast, and the like. Suitable obtained by conventional spray drying processes. Represen coffee components for use in the fourth group of embodi tative spray drying processes that provide a suitable instant ments can be prepared specifically for the formulation of the coffee for use in the fourth group of embodiments are dis flavored coffee compositions and beverages, or may be pur closed in U.S. Pat. No. 2,750.998 to Moore et al., issued Jun. chased and used “as is from a variety of commercial coffee 19, 1956; U.S. Pat. No. 2,469,553 to Hall et al., issued May houses. The roasting process in the fourth group of embodi 10, 1949; U.S. Pat. No. 2,771,343 to Chase et al., issued Nov. ments may utilize any method of heat transfer. For example, 20, 1956; and at pages 382-513 of Sivetz & Foote, Coffee convective heat transfer is typical. Roasting equipment and Processing Technology, Vol. 1, Avi Publishing Co., (1963), methods suitable for roasting coffee beans are described in, each of which is herein incorporated by reference. for example, Sivetz, Coffee Technology, Avi Publishing Co., 0330. Other suitable processes for providing an instant 1979. Additionally, U.S. Pat. No. 3,964,175, to Sivetz et al., coffee component suitable for use in the fourth group of issued Jun. 22, 1976 discloses a method for fluidized bed embodiments are disclosed in U.S. Pat. No. 3,436.227 to roasting of coffee beans. Other roasting techniques are Bergeron et al., issued Apr. 1, 1969; U.S. Pat. No. 3,493,388 described and referenced in U.S. Pat. No. 5,160,757, Kirk to Hair et al., issued Feb. 3, 1970; U.S. Pat. No. 3,615,669 to patricket al., issued Nov. 3, 1992. Hair et al., issued Oct. 26, 1971; U.S. Pat. No. 3,620,756, to 0325 Roasting may be applied until the desired roast bean Strobel et al., issued Nov. 16, 1971; and U.S. Pat. No. 3,652, color is achieved. Roast color and color differences are 293 to Lombana et al., issued Mar. 28, 1972, each of which is US 2014/0370181 A1 Dec. 18, 2014 herein incorporated by reference. In addition to spray dried the extrusion of a mixture of the flavor component together instant coffee powders, instant coffee useful in the fourth with the encapsulating material, to a spheroidizing process group of embodiments can include freeze-dried coffee. using a rotational speed of up to about 2,000 rpm in an 0331. The instant coffee components used herein will have apparatus causing centrifugal and frictional forces to be a particle density in the range of from about 0.1 g/cc to about applied to the pellets. An example of a Suitable marumerizing 0.8 g/cc, preferably from about 0.2 g/cc to about 0.5 g/cc, process is described in British Pat. Specification No. 1,361, more preferably from about 0.2 g/cc to about 0.35 g/cc. More 387, herein incorporated by reference. over, the instant coffee component will have a mean particle 0336. The encapsulating material (i.e., the material used to size distribution in the range of from about 250 microns to encapsulate the flavoring compound) may comprise one or about 2360 microns, preferably from about 500 microns to more conventional, food grade, normally solid, water-soluble about 1500 microns, more preferably from about 800 microns materials, which are generally known and used for “encapsu to about 1100 microns. Finally, the instant coffee compo lating particles in aqueous systems. Examples of such com nents, as used herein, will have a moisture level in the range of ponents include carboxymethylcellulose, ethyl cellulose, from about 1% to about 4.5%, preferably from about 1% to maltodextringelatin, gum arabic and gum agar. Crosslinking about 4%, more preferably in the range from about 1% to agents, such as TiO, and Monomide S may also be included. about 3%. 0337 Acceptable flavoring compounds may comprise 0332 Preferably, the coffee components used in the fourth natural flavors, artificial flavors, and mixtures thereof. As group of embodiments, (e.g., roast and ground, instant, and used herein, the term “natural flavors” is defined as a solid, mixtures thereof) will have a substantially non-uniform liquid, or gaseous form of a specific natural flavorant (e.g., shape, wherein the surface will be characterized by having a ground cocoa, liquid Vanilla extract, powdered almonds, and pocketed, jagged, cratered, and/or creviced morphology. the like). Mixtures of Solid, liquid, and gaseous forms of a specific natural flavorant are also acceptable. The term “natu 2. Flavoring Component in the Fourth Group of ral flavors' is also intended to encompass extracts, essences, Embodiments distillates, and oils of a given flavorant. 0333. The flavoring agents useful herein include any sub 0338. As used herein, the term “artificial flavors” includes stantially dry flavoring agent with the appropriate physical compounds capable of imparting a Substantially similar fla characteristics. As used herein, the term “substantially dry” is Vor perception to that of a desired natural flavorant (e.g., defined as having a moisture level insufficient to produce chocolate, hazelnut, mint, etc.), though the artificial flavor is “tackiness” on the surface of the compound. Suitable flavor not necessarily derived from the specific natural flavorant. It ing agents are selected from the group comprising dried fla is contemplated by the Applicants that though an artificial Voring compounds, crystalline flavor compounds, encapsu flavor Source may comprise compounds similar oridentical to lated flavoring compounds, including encapsulated liquid those found in a corresponding natural flavorant, the artificial flavoring compounds, and mixtures thereof. Preferred flavor flavor source would not contain all of the ingredients or com ing agents are encapsulated liquid flavoring compounds that pounds typically found in the natural flavorant (e.g., naturally have been treated in Such a way (e.g., by applying a coating) present compounds that would, if present, impart a dispre as to allow the resulting particle to behave as would a dry ferred flavor note or detract from the desired flavor note). flavoring compound. Additionally or alternatively, it is contemplated that the arti 0334. As used herein, the term “liquid” includes liquids, ficial flavor Source may contain the desired flavor imparting Viscous liquids, slurries, foams, pastes, gels and the like. In compound(s) as found in the naturally occurring flavorant, the compositions of the fourth group of embodiments liquid although not necessarily in the same detectable concentra flavoring compounds are encapsulated in a material compris tion. Artificial flavors may be derived from both natural and ing specifically selected materials, prior to their inclusion in synthetic processes and Sources, as those terms are known the flavored coffee composition. As used herein, the term and used in the art. “encapsulated' is broadly defined to include any method 0339 Preferred flavoring compounds include compounds whereby the flavoring component and the selected encapsu capable of delivering the following flavors: almond nut, ama lating material are comixed and are formed into discrete retto, anisette, brandy, butter rum, cappuccino, mint, cinna particles for addition into the flavored coffee composition. mon, cinnamon almond, creme de menthe, grand marnier, Thus, as used herein, the term “encapsulated includes the peppermint, pistachio, Sambuca, apple, chamomile, choco operations known in the art as prilling, encapsulating, late, cinnamon spice, cocoa, cream, butter, lavender, maple, agglomerating, noodling, comixing, coating, flaking, shred milk (in all forms), creme, vanilla, French vanilla, Irish ding, marumerizing and the like. creme, Kahlua, lemon, hazelnut, almond, pecan, lavender, 0335. One suitable method by which an additive compo macadamia nut, orange, orange leaf, peach, Strawberry, nent may be covered by an outer shell of encapsulating mate grape, raspberry, cherry, other fruit flavors, and the like, rial is described in U.S. Pat. No. 3,310,612, to Somerville et including mixtures thereof. Aroma enhancers such as acetal al., issued Mar. 21, 1967, herein incorporated by reference. A dehyde, herbs, spices, as well as mixtures of these with the prilled product can be formed by spraying a melt of the foregoing flavoring compounds may also be included. encapsulating material with the additive component into a 0340 Preferred artificial flavoring compounds include fla tower through which a cold stream of air is introduced, thus Voring compounds capable of delivering Vanilla, French causing the spray melt to Solidify into Small spheres or the Vanilla, Vanilla nut, coffee, hazelnut, Irish creme, amaretto, like. An example of such a process is described in The Chemi rum, caramel and almond flavors. In one embodiment in the cal Engineer, No. 304, December 1975, pp. 748-750, and in fourth group, preferred flavoring compounds are artificial U.S. Pat. No. 3,742,100, each which is herein incorporated by flavorants imparting a coffee or coffee-like flavor. reference. The process of marumerizing comprises the Sub 0341 The flavoring components used herein will have a jecting of flavor component-containing pellets, prepared by particle density in the range of from about 0.1 g/cc to about US 2014/0370181 A1 Dec. 18, 2014 20
0.8 g/cc, preferably from about 0.3 g/cc to about 0.6 g/cc, have an ingredient composition similar to that of the foaming more preferably from about 0.4 g/cc to about 0.5 g/cc. More creamers but without the incorporated gas. Also, foaming over, the flavoring components will have a moisture level in creamers typically have more proteinaceous components the range of from about 1% to about 7%, preferably from (typically about 12-13% of total ingredients) relative to non about 1% to about 5.5%, more preferably from about 1% to foaming non-dairy creamers (typically about 3.5% of total about 4%. ingredients). 0342 Suitable flavoring components for use in the fourth 0347 ii) Aroma Enhancers group of embodiments will have a mean particle size distri 0348 Aroma enhancers such as acetaldehyde, herbs, bution in the range of from about 5 microns to about 150 spices, and the like, may be included in the flavored coffee microns, preferably from about 30 microns to about 100 compositions of the fourth group of embodiments. microns, more preferably from about 40 microns to about 60 microns. (0349 iii) Sweeteners 0350 A sweetener or combination of Sweeteners may be 3. Optional Ingredients in the Fourth Group of Embodiments useful for Sweetening the flavored coffee compositions of the fourth group of embodiments. Such Sweeteners include natu (0343 i) Creamers ral and artificial sweeteners and combinations thereof. Suit 0344) The flavored coffee compositions in the fourth able natural sweeteners useful in the fourth group of embodi group of embodiments may optionally contain one or more ments include, but are not limited to Sucrose, fructose, creamers. As used herein, the term “creamer” refers to an dextrose, maltose, lactose, and mixtures thereof. Suitable additive used in many ready-to-drink and instant beverage artificial Sweeteners include, but are not limited to saccharin, products. Commercial creamers are readily available, and are cyclamates, acesulfame K (Sunette R), L-aspartyl-L-pheny readily chosen by those of ordinary skill in the art. Prepared lalanine lower alkyl ester Sweeteners (e.g. Aspartame(R): creamers generally comprise fat, emulsifiers, and processing L-aspartyl-D-alanine amides disclosed in U.S. Pat. No. aids. Accordingly, the beverage compositions of the fourth 4.411.925 to Brennan et al.: L-aspartyl-D-serine amides dis group of embodiments may utilize creamers and, depending closed in U.S. Pat. No. 4.399,163 to Brennan et al.: L-aspar on the composition of the particular creamer chosen, all or tyl-L-1-hydroxymethylalkaneamide Sweeteners disclosed in part of the fat, emulsifier or processing aids used in the com U.S. Pat. No. 4.338,346 to Brand; L-aspartyl-1-hydroxyethy position can be, in fact, contributed by the creamer. alkaneamide sweeteners disclosed in U.S. Pat. No. 4,423,029 0345 Suitable creamers for use in the flavored beverage to RiZZi; and L-aspartyl-D-phenylglycine ester and amide products of the fourth group of embodiments include dairy Sweeteners disclosed in European Pat. Application 168,112 to and non-dairy creamers. Suitable dairy creamers include J. M. Janusz, published Jan. 15, 1986; and the like and mix whole milk solids; butterfat solids; low-fat dry milk; and dry tures thereof. mixes used to prepare ice cream, milkshakes, and frozen 0351) iv) Thickeners desserts, as well as mixtures of these dairy creamers. Suitable 0352 Flavored coffee compositions according to the non-dairy creamers can be made from a variety offats and oils fourth group of embodiments can comprise thickening including soybean and partially-hydrogenated Soybean oil, agents. These thickening agents can include natural and Syn partially-hydrogenated canola oil, hydrogenated and par thetic gums, and natural and chemically modified Starches. tially-hydrogenated coconut oil, as well as other partially- or Suitable gums include locust bean gum, guar gum, gellan fully-hydrogenated vegetable oils, or combinations of Such gum, Xanthan gum, gum ghatti, modified gum ghatti, traga oils. Preferred creamers include non-dairy creamers made canth gum, carrageenan, and/or anionic polymers derived from vegetable oils, emulsifiers, co-emulsifiers, carbohy from cellulose such as carboxymethylcellulose, Sodium car drates, sodium caseinate, and buffers. Additional creamers boxymethylcellulose, as well as mixtures of these gums. Suit suitable for use in the fourth group of embodiments include able starches include, but are not limited to pregelatinized those synthetic and imitation dairy products disclosed in starch (corn, wheat, tapioca), pregelatinized high amylose KIRK-OTHMER ENCYCLOPEDIA OF CHEMICAL content starch, pregelatinized hydrolyzed starches (malto TECHNOLOGY, W.J. Harper, Willey Interscience, 3rd edi dextrins, corn syrup Solids), chemically modified Starches tion, Vol. 22, section entitled “Synthetic and Imitation Dairy Such as pregelatinized substituted Starches (e.g., octenyl Suc Products. pp. 465-498, (1978) of which is herein incorpo cinate modified starches such as N-Creamer, N-Lite LPTEX rated by reference. TRA, manufactured by National Starch), as well as mixtures 0346 Both foaming and non-foaming creamers can be of these starches. It is particularly preferred that thickening used in the flavored beverage products of the fourth group of agents be predominantly made from starches and that no embodiments. Foaming creamers suitable for use in the more than about 20%, most preferably no more than about fourth group of embodiments can comprise a non-dairy fat 10%, of the thickener be made from gums. These thickening (e.g., partially hydrogenated oil), a water-soluble non-dairy agents can also be incorporated into these flavored beverage carbohydrate (e.g., Sucrose, dextrose, maltose, corn syrup products as part of the carrier for the emulsified fat on the Solids and mixtures thereof), a buffer, a proteinaceous foam spray dried non-foaming creamer. stabilizing agent (e.g., sodium caseinate) and/or optionally a gum thickener. These solid components can be mixed with C. Flavored Coffee Compositions and Method of Making in water and then homogenized. A gas (e.g., nitrogen) can be the Fourth Group of Embodiments injected or blended into this mixture and the mixture is spray dried to provide the foaming creamer. See U.S. Pat. No. 0353. The flavored coffee compositions of the fourth 4,438,147 (Hedrick, Jr.), issued Mar. 20, 1984; and U.S. Pat. group of embodiments comprise a flavoring component in No. 5,462,759 (Westerbeeketal), issued Oct. 31, 1995, each intimate contact with a coffee component, wherein said com of which is herein incorporated by reference. Non-foaming ponents remain in contact with each other without the use of creamers suitable for use in the fourth group of embodiments an agglomerating solution or binding agent. US 2014/0370181 A1 Dec. 18, 2014
0354. The ratio of the coffee component to the flavoring roast and ground, instant, or mixtures thereof) may be component is determined by the desired degree of flavor selected first and then a Suitable flavoring component could impact and flavor loading/concentration. Preferably, the fla be identified using the same criteria. vored coffee compositions of the fourth group of embodi 0360 Once suitable coffee components and flavoring ments comprise from about 80% to about 99.5%, on a dry components are identified and selected, they are mixed weight basis, of the coffee component, and from about 0.5% together. One of ordinary skill in the art will appreciate that to about 20%, on a dry weight basis, of a flavoring compo any mixing apparatus or process that imparts sufficient nent. In preferred embodiments, the flavored coffee compo mechanical energy to allow the coffee and flavoring particles sitions comprise from about 85% to about 98% of a coffee to tumble over each other is acceptable. Suitable mixing component and from about from about 2% to about 15% of a devices include ribbon, plough, Screw, and paddle type mix flavoring component, more preferably the compositions com CS. prises from about 90% to about 97% of a coffee component 0361. The particles of the coffee and flavoring compo and from about 3% to about 10% of a flavoring component; nents are mixed together for a time Sufficient to provide a yet more preferably from about 92% to about 96% of a coffee flavored coffee composition with a desired Distribution component and from about 4% to about 8% of a flavoring Value, utilizing the Distribution Value Determination method component. described herein. 0355 The desired mean particle size distribution of the 0362. It will be appreciated by one of ordinary skill in the coffee component particles and the flavoring component par art that some steps of the above described process may be ticles of the fourth group of embodiments is determined in avoided, additional steps may be added, or the sequence of part by the exact type of coffee component and flavoring steps may altered without deviating from the scope of the component selected for use. The ratio of the mean particle fourth group of embodiments. size distribution of the coffee component to the mean particle size distribution of the flavoring component is in the range of D. Segregation and Distribution Value in the Fourth Group of from about 100:1 to about 5:1, preferably from about 50:1 to Embodiments about 5:1, more preferably from about 25:1 to about 6:1, yet more preferably from about 15:1 to about 7:1. 0363 Segregation and separation of flavoring component 0356. Not intending to be limited by theory, the inventors particles from the coffee component particles and the bulk of believe that the flavoring component particles remain in con the flavored coffee composition mass is caused by a variety of tact with the coffee component particles because of the par factors experienced during production, processing, packag ticle size ratios and a combination of forces, including fric ing, shipping, storage, and dispensing. Of these factors, the tional forces and van der Waals forces. most notable are vibration, percolation, trajectory of falling 0357 “van der Waals forces are defined as the series of particles, angle of repose, and impact on a heap. In the fla attractive forces between unlike charged molecules or mac vored coffee compositions of the fourth group of embodi romolecules. These electronic forces are based on the chang ments, it is critical to inhibit the segregation or separation of ing electronic charge (i.e., momentary dipoles) of a molecule, particles in order to ensure a consistent flavor impact over the induced electronic charge (i.e., induced dipole) of a mol multiple serving portions. For a more detailed discussion of ecule or the permanent electronic charge (i.e., symmetrical segregation see Handbook of Powder Science & Technology, dipole) of a molecule contacting another molecule or macro 2nd Edition, Edited by Fayed & Otten, International Thom molecule of an opposite charge. son Publishing, 1997, pp. 446-453, herein incorporated by 0358 It is believed that the electronegative material of the reference. flavoring compound, or encapsulating material of an encap 0364 The degree of segregation or separation is measured Sulated flavoring compound, is attracted to the less polar using a Distribution Value. As used herein, the term “Distri coffee particle. The tumbling action of the particles during bution Value' is defined as the numerical representation of the mixing provides the mixture enough energy to effectively degree to which the flavoring component particles are distrib allow each of the flavor component particles to move around uted throughout the flavored coffee compositions, or segment the coffee until an area of positive charge (i.e., a bonding site) thereof. The Distribution Value is represented as a percentage is located. From that point forward the flavor particle and the relative standard deviation (DV% RSD), where a completely coffee particles remain in intimate contact until a more elec uniform distribution would be represented as 0%. RSD. tronegative force breaks them apart (e.g., when water contacts 0365. In the flavored coffee compositions of the fourth the coffee and solubilizes the flavor component particles). For group of embodiments, a Distribution Value of less than about a more detailed discussion see Organic Chemistry, 3rd Edi 50% RSD is preferred, a Distribution Value of less than about tion, Morrison & Boyd pp. 3-4, herein incorporated by refer 30% RSD is more preferred, a Distribution Value of less than CCC. about 20% RSD is still more preferred, and a Distribution 0359. In preparing the non-agglomerated flavored coffee Value of less than about 10% RSD is most preferred. compositions contemplated by the fourth group of embodi ments, the desired flavoring component is typically selected Analytical Methods in the Fourth Group of Embodiments first. Based on the intended flavor impact, the type of flavor ing component(s) selected (e.g., Solid, crystalline, encapsu 0366 A. Distribution Value Determination lated liquid, etc.) the corresponding physical characteristics 0367 The Distribution Value is defined herein as the (e.g., particle size, particle density, particle moisture, etc.) numerical representation of the degree to which the particles and component morphology (e.g., pocketed, jagged, cratered, of the flavoring component are distributed throughout the and/or creviced), a suitable coffee component is selected. flavored coffee compositions, or segment thereof. The gen However, it will be appreciated by one skilled in the art, upon eral process of measuring a given Distribution Value is char reading the disclosure herein, that the coffee component (e.g., acterized by the steps of: US 2014/0370181 A1 Dec. 18, 2014 22
0368 (1) Developing and validating a partial least squares tion sample level is analyzed in triplicate under the following regression calibration model for the specific flavor compo conditions: 1.00+/-0.05 grams of the sample was weighed nent(s) to be used in the flavored coffee composition. into a standard 10 milliliter headspace vial and sealed using a 0369 (2) Analyzing the Flavored Coffee Composition of crimp top lid. The vials are then placed into the Agilent 4440 interest by the process steps of Chemical Sensor for analysis. Within the chemical sensor the 0370 (i) providing a flavored coffee composition of inter sample is equilibrated at 85°C. for 20 minutes and the head est; space is sampled and transferred into a 3-milliliter sample 0371 (ii) preparing and analyzing at least three (3) dis loop. The carrier stream is then opened to the loop and the crete samples of the flavored coffee composition on an Agi headspace is swept into the mass spectrometer for analysis. lent Model 4440 mass spectroscopy (MS) sensor; 0380. The headspace autosampler conditions used are as 0372 (iii) providing a partial least squares regression follows: model, using chemometric techniques, for the specific flavor (0381 i) sample oven: 85°C.: component(s) used in the preparation of the flavored coffee (0382 ii) valve oven/loop: 105° C.; composition; 0383) iii) MS interface 120° C.; 0373 (iv) using the developed partial least squares regres 0384 iv) vial pressure 13.8 psi; sion model to calculate predicted flavor addition levels for the 0385 V) carrier gas (Helium) pressure 1.8 psi; analyzed samples: 0386 vi) loop equilibration time: 0.05 minutes; 0374 (V) calculating the mean and standard deviation of 0387 vii) vial pressurization time: 0.20 minutes: the output of the discrete samples; and, (0388 viii) loop fill time: 0.20 minutes: 0375 (vi) applying Equation 1 to the resulting data to (0389) ix) inject time 1.00 minutes generate a Distribution Value. 0390 The MS conditions areas follows: Distribution Value=Standard Deviationx(100/mean) Equation 1 0391 i) mass range 50-150 amu: 0392 ii) split flow to MS 43.8 milliliters: Calibration Process 0393 iii) solvent delay 0.45 minutes: 0376. In order to accurately determine the Distribution 0394 iv) run time 1.10 minutes: Values for a flavored coffee composition of interest, it is 0395 v) threshold 150; necessary to develop a calibration model for the flavor com 0396 vi) sampling value 2, 10.26 scans/second. ponent(s) used in the flavored coffee composition. The first 0397. The data generated from the mass spectroscopy pro step in the process is to provide a suitable Coffee Component cedure is then processed and analyzed using a commercial as the base for a flavored coffee composition calibration chemometrics spectral analysis program called Pirouette sample set. Suitable coffee components are those coffee com (Pirouette by Information, Inc. of Woodville, Wash.). The ponents as described herein. Secondly, a suitable flavor com chemometric analysis program is used to develop a partial ponent is provided. Suitable flavor components, as described least squares regression calibration model. A discussion of herein, comprise Volatile components which would evaporate partial least square (PLS) regression models and techniques into any available packaging headspace. Suitable flavor can be found in Applied Spectroscopy Reviews, Vol. 31 Sources will also exhibit at least one mass fragment differ (1&2), pp. 73-124 (1996) by Workman et al. which is herein ence, under MS analysis, from those of the provided coffee incorporated by reference. SOUC. 0398 Chemometrics is the application of mathematical 0377 Next, a calibration sample set is prepared by com and Statistical methods to extract more useful chemical infor bining the provided coffee component(s) and flavor compo mation from chemical and physical measurement data. nent(s) to make at least 3 discrete calibration samples of a Chemometrics applies computerized data analysis tech flavored coffee composition. At least one calibration sample niques to help find relationships between variables among must contain the same amount of flavor component as is large Volumes of raw data. Standard practices for infrared, contained in the flavored coffee composition, which is to be multivariate, quantitative analysis are described in the analyzed for its Distribution Value. At least one calibration “American Society for Testing Materials (ASTM) Practice sample must contain an amount of flavoring component, E1655-94 (1995); ASTM Annual Book of Standards, West which is less than the amount in the flavored coffee compo Conshohocken, Pa. 19428-2959 USA, Vol. 03.06: The Asso sition that is to be analyzed. Furthermore, at least one cali ciation of Official Analytical Chemists (AOAC) Official bration sample must contain an amount of flavoring compo Methods of Analysis, 15th Ed. (1990), pp. 74-76, each of nent in excess of the flavored coffee composition, which is to which is incorporated herein by reference. be analyzed. 0399. After the calibration model is developed it is vali 0378 For example, if the flavored coffee composition of dated utilizing cross validation techniques, whereby the interest (i.e., the flavored coffee composition to be measured model is progressively developed by sequentially omitting 1 for its Distribution Value) is believed to contain 2% by weight sample from analysis and then that sample is used for predic of a flavor component, then one calibration sample should be tion. Performance statistics are accumulated for each group of mixed with 2%, by weight of the flavor component, the sec removed samples. The optimum number of factors contained ond calibration sample should contain a smaller amount by within the calibration model is determined by the number of weight of the flavor component (e.g., preferably 1%), and the factors which produces a minimum in overall error between third calibration sample should contain a flavor component modeled and referenced values (standard error of cross vali amount in excess of the 2% contained in the flavored coffee dation SECV) for the samples removed during cross vali composition of interest (e.g., 3%). dation. The preprocessing transformations used were the 0379 The calibration sample sets are then analyzed using optimum required to improve the SECV compared to PLS mass spectroscopy equipment and techniques. Each calibra analysis with untransformed data. US 2014/0370181 A1 Dec. 18, 2014
04.00 Determination of Distribution Values During/Fol ticles and also decaffeinated forms thereof. Such a product is lowing Coffee Composition Mixing composed of clearly defined cells providing a distinct struc 04.01 The Distribution Value for the flavoring component ture defined by the individual cell walls. The invention also in the flavored coffee composition of the fourth group of contemplates light-milled, cell-distorted roast and ground embodiments, either during or following mixing, is deter coffee referred to as “light-milled coffee’; as well as “flaked mined according to the following process: roast and ground coffee'. While light-milled coffee and 0402 i) Provide flavored a flavored coffee composition flaked coffee are both produced by roll milling roast and with a flavor component addition level between the upper and ground coffee, the two products are to be distinguished. lower values used to create the calibration model (e.g., 1%, Light-milled coffee, as the name implies, is produced by 2%. 3%, etc.); generally using low roll mill pressures. From the cell struc 04.03 ii) Select at least 3 samples of the flavored coffee ture point of view light-milled coffee has partial cell wall composition from different regions of the mixer, and at least fracture, partial cell disruption and cells, which have gener 1 sample randomly drawn from the composition following ally been flattened and compressed together to provide weak mixing: ened and distorted but still definite cell structure. Flaked 0404 iii) Run samples on the MS Sensor; samples are a coffee, on the other hand, is produced by utilizing generally 1.0 gram sample weight and are analyzed in triplicate under higher roll mill pressures to produce an easily definable flake the same conditions and instrument settings as described in shape, which has nearly total cell disruption. In other words, the calibration sample sets; speaking in general terms, light-milled coffee has weakened 0405 iv) Use chemometric model to calculate flavor level cell walls and partial cell disruption whereas flaked coffee has from raw data; crushed cell walls and nearly total cell disruption. These 0406 v) Calculate mean and standard deviation of differences can conveniently be seen when examining photo samples; and, micrographs. 0407 vi) Using Equation 1 to calculate a Distribution 0419. The coffee in the coffee composition 110/130 and Value. beverage material 120 as shown in FIGS. 1A, 1B, and 1C may 0408 Determination of Distribution Values During/Fol result from any Suitable milling treatment before, during, lowing Shipping and/or after the roasting, and/or grinding step(s). The fifth 04.09. The Distribution Value for the flavoring component group of embodiments, according to the present invention, is in the flavored coffee compositions of the fourth group of related to light-milled, cell-distorted roast and ground coffee. embodiments, either during or following shipping, is deter The light-milled coffee has a bulk density equal to that of mined according to the following process: conventional roast and ground coffee products. The product 0410 i) Provide flavored a flavored coffee composition has some cell fracture and partial cell disruption and therefore with a flavor component addition level between the upper and has increased extractability. The light-milled, cell-distorted lower values used to create the calibration model (e.g., 1%, roast and ground coffee, when viewed in bulk, has the appear 2%. 3%, etc.); ance of conventional roast and ground coffee but has from 10 0411 ii) Pack the flavored coffee composition into a to 30% increase in flavor strength. The method of producing selected package (can or plastic container). this product comprises passing roast and ground coffee 0412 iii) Place the packaged products onto a standard through a roll mill under controlled conditions of feed rate, shipping Support (pallet). Perform ship test using Test pressure, and roll speed. Method D51 12-98, Standard Test Method for Vibration 0420. The fifth group of embodiments relates to light (Horizontal Linear Sinusoidal Motion) Test of Products, from milled, roast and ground coffee, which has the same bulk the American Society for Testing and Materials, West Con appearance as conventional roast and ground coffee particles shohocken, Pa. as well as the same bulk density as conventional roast and 0413 iv) Select at least 3 samples of the flavored coffee ground coffee particles, but which has from 10 percent to 30 composition from different regions of the mixer, and at least percent increase in flavor strength over and above conven 1 sample randomly drawn from the composition following tional roast and ground coffee products. The fifth group of mixing: embodiments also relates to a method of making light-milled 0414 v) Run samples on the MS Sensor; samples are a 1.0 roast and ground coffee, which comprises passing roast and gram sample weight and are analyzed in triplicate under the ground coffee through a roll mill within a range of carefully same conditions and instrument settings as described in the defined coffee feed rates, roll mill pressures, and roll periph calibration sample sets; eral Surface speeds. 0415 vi) Use chemometric model to calculate flavor level 0421. In connection to the background of the fifth group of from raw data; embodiments, flaked coffee per se is known in the art (see 0416 vii) Calculate mean and standard deviation of McKinnis, U.S. Pat. No. 1,903,362, Rosenthal, U.S. Pat. No. samples; and, 2,123,207, and Carter, U.S. Pat. No. 2,368,113). Light-milled 0417 viii) Using Equation 1 to calculate a Distribution roast and ground coffee, which when viewed in bulk has the Value. appearance and bulk density of conventional roast and ground coffee but has from 10% to 30% increase in flavor strength, Post-Grinding Treatment: Cell Structure Engineering has notheretofore been known in the art. 0418. In preparing the coffee composition for use in a 0422 U.S. Pat. No. 3,615,667, of Joffe, entitled beverage unit as defined in the Summary of the Invention, the FLAKED COFFEE AND PRODUCTS PRODUCED coffee in the coffee composition 110/130 and beverage mate THEREFROM, relates to the flaking of roast and ground rial 120 as shown in FIGS. 1A, 1B, and 1C may have various coffee as a means of advantageously controlling and regulat cell structures. For example, roast and ground coffee com ing the flavor and aroma of coffee as well as the extractability prises conventionally prepared roast and ground coffee par of coffee. The Joffe patent discloses utilizing the varying US 2014/0370181 A1 Dec. 18, 2014 24 effect of flaking on high, low, and intermediate grade coffees, 0427. Another aspect of the fifth group of embodiments as a method of making an improved roast coffee product provides a coffee composition for use in a beverage unit and comprising as a major portion low and/or intermediate grade method thereofas defined in the Summary of the Invention, coffee flakes, and as a minor portion, high grade roast and wherein the coffee composition comprises a light milled roast ground coffee. An additional application of McSwiggin et al. and ground coffee, which has a bulk appearance of conven entitled “A METHOD OF MAKING FLAKED ROAST tional roast and ground coffee particles and, which has 10 to AND GROUND COFFEE Ser. No. 823,942, filed May 12, 30% increase in flavor strength over an equivalent amount of 1969 now U.S. Pat. No. 3,660,106, discloses preferred con conventional roast and ground coffee particles; made from a ditions for making flaked roast and ground coffee. method comprising passing roast and ground coffee through 0423. The flaked coffee product and processes disclosed a roll mill at a roll pressure of from 750 pounds/inch of nip to in the above identified applications are excellent products 1,400 pounds/inch of nip, at a roll peripheral surface speed of from the standpoint of Versatility and consumer acceptance. from 200 feet/minute to 350 feet/minute and at a roast and However, it is often of an advantage to provide a series of ground coffee feed rate to the mill of from 100 pounds/hour products each having its own distinctive characteristics. per inch of nip to 275 pounds/hour per inch of nip. For Moreover, for those people who have become familiar with example, the roll mill surface temperature may be from 50°F. conventional roast and ground coffee, it is at times of a defi to 2009 F., such as from 90°F. to 180° F. nite advantage to provide a product having that same appear 0428 Still another aspect of the fifth group of embodi ance. Light-milled roast and ground coffee has the bulk ments provides a coffee composition for use in a beverage appearance of conventional roast and ground coffee and, Sur unit and method thereof as defined in the Summary of the prisingly, the same bulk density, and yet has from 10 percent Invention, wherein the coffee composition comprises a light to 30 percent increase in flavor strength over and above con milled roast and ground coffee which has a bulk appearance ventional roast and ground coffee. It should be noted that of conventional roast and ground coffee particles and which light-milled coffee is characterized as having the “bulk has 10 to 30% increase in flavor strength over an equivalent appearance' of roast and ground coffee. While individual amount of conventional roast and ground coffee particles; particles may by pure chance have the geometric shape of a made from a method comprising passing roast and ground flake, they all differ from flakes in cell characterization and coffee through a roll mill at a roll pressure of from 850 extractability characteristics and, when viewed in bulk, give a pounds/inch of nip to 1,700 pounds/inch of nip, at a roll visual impression distinct from flakes and very much like peripheral surface speed of from 350 feet/minute to 600 feet/ roast and ground coffee. minute and at a roast and ground coffee feed rate to the mill of from 275 pounds/hour per inch of nip to 400 pounds/hour per 0424. It is an object of the fifth group of embodiments to inch of nip. For example, the roll mill surface temperature provide light-milled roast and ground coffee, which has the may be from 50° F. to 200°F., such as from 90°F. to 180° F. bulk appearance of conventional roast and ground coffee 0429. A further aspect of the fifth group of embodiments particles, the same bulk density as conventional roast and provides a beverage unit and method thereofas defined in the ground coffee particles and, yet, which is from 10 percent to Summary of the Invention, wherein the coffee composition 30 percent greater in flavor strength than conventional roast comprises a light milled roast and ground coffee which has a and ground coffee. bulk appearance of conventional roast and ground coffee 0425 One aspect of the fifth group of embodiments pro particles and which has 10 to 30% increase in flavor strength vides a coffee composition for use in a beverage unit and over an equivalent amount of conventional roast and ground method thereofas defined in the Summary of the Invention, coffee particles; made from a method comprising passing wherein the coffee composition comprises a light-milled roast and ground coffee through a roll millata roll pressure of roast and ground coffee having a bulk appearance and density from 1,000 pounds/inch of nip to 2,000 pounds/inch of nip, at like that of roast and ground coffee but providing from about a roll peripheral surface speed of from 600 feet/minute to 750 10% to about 30% increased flavor strength over an equiva feet/minute and at a roast and ground coffee feed rate to the lent amount of roast and ground coffee; said light-milled roast mill of from 400 pounds/hour per inch of nip to 550 pounds/ and ground coffee obtained by a process comprising: hour per inch of nip. For example, the roll mill surface tem 0426 passing roast and ground coffee through a roll mill perature may be from 50° F. to 200°F., such as from 90°F. to under one of a three-variable set of mutually exclusive pro 180° F. cessing conditions; said mutually exclusive processing sets 0430. The fifth group of embodiments as described above comprising: a roll pressure of from 750 pounds/inch of nip to will be further described in the following paragraphs and 1,400 pounds/inch of nip, at a roll peripheral surface speed of exemplified in Examples 18-20. Informing light-milled roast from 200 feet/minute to 350 feet/minute, and at a roast and and ground coffee, roast and ground coffee is Subjected to ground coffee feed rate to the mill of from 100 pounds/hour mechanical pressure by passing conventional roast and per inch of nip to 275 pounds/hour per inch of nip; a roll ground coffee particles through two parallel Smooth or highly pressure of from 850 pounds/inch of nip to 1,700 pounds/inch polished rolls so that the coffee particles passing between the of nip, at a roll peripheral surface speed of from 350 feet/ rolls are subjected to sufficient stress in order to provide the minute to 600 feet/minute at a roast and ground coffee feed previously described cell distortion, i.e., partial cell fracture, rate to the mill of from 275 pounds/hour per inch of nip to 400 partial cell disruption, Some cell flattening and compression pounds/hour per inch of nip; a roll pressure of from 1,000 and generally a weakened and distorted but still definite cell pounds/inch of nip to 2,000 pounds/inch of nip at a roll Structure. peripheral surface speed of from 600 feet/minute to 750 feet/ 0431. In roll milling roast and ground coffee to produce minute at a roast and ground coffee feed rate to the mill of light-milled coffee, it has been found important to control from 400 pounds/hour per inch of nip to 500 pounds/hour per several process variables besides pressure. These additional inch of nip, respectively. variables which are essential to control within hereinafter US 2014/0370181 A1 Dec. 18, 2014
defined ranges include roast and ground coffee feed rate to the TABLE mill and roll peripheral surface speed. Other variables of less importance from the standpoint of producing a light-milled Pressure, Roll speed, Feed rate, coffee but still important from an overall efficiency stand Set No. Ibs.fin. ft./min. lbs./hr.fin. point include mill diameter, coffee moisture content and par 1 7SO-1400 200-350 100-275 2 850-1700 350-600 275-400 ticle size, and roll Surface temperature. 3 1OOO-2OOO 600-7SO 400-SSO 0432. The three most important factors in the fifth group of embodiments, which must be controlled in producing light 0436 The important factor to remember is that within milled, cell-fractured roast and ground coffee are the roll each given set of conditions, operation at points within the pressure, the roast and ground coffee feed rate, and roll expressed ranges will produce light-milled coffee. The over peripheral Surface speed. Roll pressure is measured in lap of ranges occurs because of the non-linear and non-planar pounds/inch of nip. Nip is a term used in the art to define the relationship that exists. For example, at a roll pressure of 2,000 lbs./inch of nip and a roll speed of 700 ft/min., a 0.012 length of surface contact between two rolls when the rolls are inch thickness flake will be produced at a feed rate of 100 at rest. To illustrate, it can be thought of as a line extending the lbs./hr./inch, a 0.020 inch thickness flake will be produced at full length of the rolls and defining the point of contact a feed rate of 300 lbs./hr./inch and light-milled coffee will be between two rolls. Feed rate as used herein is defined as the produced at a feed rate of 550 lbs./hr./inch. In like manner, at pounds of roast and ground coffee per hour passing through a roll speed of 700 ft./min. and a feed rate of 445 lbs./hr./inch, each inch of nip. The third variable, roll peripheral surface a 0.27 inch thickness flake will be produced at a pressure of 2,200 lbs./inch of nip; light-milled coffee will be produced at speed, is measured in feet/minute of Surface circumference 1,400 lbs./inch of nip; and at a pressure of 660 lbs./inch of nip which passes by the nip. Generally, higher peripheral speeds roast and ground coffee passing through the mill will remain mean that pressures within the lower portion of the hereinaf unchanged in terms of cell characterization. Thus, as can be ter described ranges can be employed to produce satisfactory seen from the above specific examples only conditions of light-milled coffee of the requisite bulk density. Conversely, pressure, roll peripheral surface speed and coffee feed rate at lower peripheral speeds pressures at or near the higher end falling wholly within a single one of the above sets specified of the hereinafter described ranges must be employed to in the Table, as opposed to falling within the entire range of produce light-milled coffee of the requisite bulk density. conditions expressed amongst all three sets, Will assure preparation of light-milled coffee. Put still another way, 0433. In further regard to roll peripheral surface speeds, it where pressure, roll speed and feed rate fall wholly within set should be mentioned that it is preferred in the fifth group of No. 3 of conditions, light-milled coffee will result, but where embodiments that the individual rolls of the roller mill be both pressure and roll speed fall within the ranges for set No. operated at the same speeds. Differential roll speeds, how 3 conditions and the feed ratefalls within set No. 1 conditions, ever, can be utilized. If differential roll speeds are utilized, roll the result may be a flake (see the first example given in this speed ratios in excess of 1.5:1 are not desirable. Preferably, paragraph). when differential roll speeds are employed the roll speed rate 0437. It should be understood that as roll speed is is within the range of 1:1 to 1.4:1. increased beyond 750 ft/min., if pressure is increased beyond 2,000 lbs./inch and feed rate is increased beyond 550 lbs./hr./ 0434. It is to be understood that the three important vari inch, some light-milled coffee may be formed. Likewise, as ables in fifth group of embodiments, i.e. pressure, roll speed pressure is reduced below 750 lbs./inch and roll speed is and feed rate, are all interrelated and act in a combined man reduced below 200ft./min. and feed rate is reduced below 100 ner to produce light-milled coffee. Thus, within a given range lbs./hr./inch, some light-milled coffee may be produced. for a single variable manipulation within a corresponding However, Such conditions are not practical because of the range must occur for the other two variables in order to insure resulting low capacities. preparation of light-milled coffee rather than flakes. For 0438 Roll surface temperature, as used herein, is mea example, as feed rate is increased the pressure and roll speed Sured in degrees Fahrenheit, and refers to the average Surface must also be increased to continue production of light-milled temperature of the rolls. Control of the roll mill surface tem coffee as that product is defined herein. perature is accomplished by controlling the temperature of a 0435 Because the relationship of the important variables heat exchange fluid passing through the inner core of the rolls. includes three determinations, i.e., pressure, roll speed and Generally, the fluid, which is most often water, is heated or feed rate, it cannot adequately be presented on two-dimen cooled and passed through the inside of the rolls. The result is sional graphic illustration. Moreover, because the interdepen that the roll Surface, which is usually a smooth, highly pol dence of these three variables in producing light-milled cof ished steel surface, is subjected to temperature control by fee is not a linear relationship but rather a curved line means of heat transfer. Of course, in actual operation the relationship, they cannot be expressed as absolute ranges, the Surface temperature will not be exactly the same as the tem entire scope of which will produce light-milled coffee. Of perature of the heat exchange fluid, and will be somewhat course, this non-straight line relationship and non-planar higher because milling of coffee particles to produce light (three-dimensional as opposed to two-dimensional) relation milled coffee tends to increase the roll surface temperature. ship makes definition difficult. However, by experimentation Accordingly, the required heat exchange fluid temperature to it has been found that the relationships shown in the following maintain any specific roll Surface temperature depends upon Table will produce the desired light-milled product. The three several factors, such as the kind of metal the roll surfaces are sets of relationships presented in the Table below represent an made of the speed of operation of the roll mills, and the heat experimental integration of a plurality of data points. exchange fluid employed. US 2014/0370181 A1 Dec. 18, 2014 26
0439 Generally, it can be stated that higher roll surface ity exists. However, from the standpoint of producing prod temperatures tend to increase the propensity for flavor deg ucts of a bulk density similar to that of conventional roast and radation of the light-milled, roast and ground coffee, and ground coffee, it is preferred that the roast and ground coffee therefore should be avoided. On the other hand, lower roll particles be of conventional size distributions; that is, have a Surface temperatures can be employed without disadvan particle size of from 0.0 to 18.0% retained on a 12 mesh U.S. tages. However, no particular advantage is gained in utilizing Standard Screen, from 0.0 to 46.0% retained on a 16 mesh temperatures below room temperatures so that a cooling U.S. Standard Screen, from 15.0 to 50.0% retained on a 20 medium must be employed. Generally, satisfactory light mesh U.S. Standard Screen, from 7.0 to 30.0% retained on a milled coffee can be produced wherein the roll surface tem 30 mesh U.S. Standard Screen, from 4.0 to 15.0% retained on perature is within the range of from 50° F. to 200°F. Tem a 40 mesh U.S. Standard Screen, and from 3.0 to 8.0% pass peratures less than 50 F. are undesirable because cooling ing through a 40 mesh U.S. Standard Screen. Speaking in systems must be employed and the resulting product tends to more familiar terms, the roast and ground coffee to be light be quite brittle and easily fractured to produce large quantities milled can be “regular”, “drip’ or “fine grind as these terms of coffee fines, which are undesirable because they result in a are used in a traditional sense. The standards of these grinds as change in product bulk density. Temperatures above 200°F. suggested in the 1948 Simplified Practice Recommendation should be avoided because at temperatures elevated above by the U.S. Department of Commerce (see Coffee Brewing 200 F. noticeable degradation of coffee flavor occurs. To Workshop Manual, page 33, published by the Coffee Brewing produce light-milled coffee having a bulk density, which is Center of the Pan American Bureau are as follows: “Regular essentially the same as that of roast and ground coffee without grind', 33% is retained on a 14 mesh Tyler Standard Sieve, noticeable flavor degradation, it is preferred that the roll mill 55% is retained on a 28 mesh Tyler Standard Sieve and 12% surface temperature be within the range of 90° F to 180° F. passes through a 28 mesh Tyler Standard Sieve; "drip grind', When roll surface temperatures are within this range the 7% is retained on a 14 mesh Tyler Standard Screen, 73% on a majority of the resultant cell-fractured, light-milled coffee is 28 mesh Tyler Standard Sieve and 20% passes through a 28 of a proper structural integrity to insure a bulk density near mesh Tyler Standard Sieve; and “fine grind 100% passes that of roast and ground coffee coupled with a product which through a 14 mesh Tyler Standard Sieve, 70% being retained exhibits little or no flavor degradation. on a 28 mesh Tyler Standard Sieve and 30% passing through 0440. In the fifth group of embodiments, the bulk density a 28 mesh Tyler Standard Sieve. Of the above mentioned of roast and ground coffee is generally within the range of traditional grind sizes, the most preferred is “regular grind.” from 0.38 g/cc to 0.50 g/cc, and most often within the pre 0443) In further regard to particle size, it has previously ferred range of from 0.42 g/cc to 0.48 g/cc. Such bulk densi been mentioned that the light-milled, cell-fractured coffee ties are generally those of conventionally prepared roast and product of the fifth group of embodiments has a bulk density ground coffees of regular, drip, and fine grinds. If the light Substantially similar to that of conventional roast and ground milled product bulk density varies from this range and is, for coffee. In other words, it is important to remember that the example, higher, the consumer would need to use Substan light milling process of the fifth group of embodiments does tially less than usual quantities of coffee to produce a brew of not involve bulk density change but merely changes the indi given strength. This required adjustment in consumer habits vidual cell characteristics. The input of conventional roast might be met with difficulty, and therefore careful attention is and ground coffee particles has the same bulk density as the given to producing product having a bulk density similar to output of light-milled coffee, the only difference being that that of roast and ground coffee so that familiar measurement the output, despite the fact that it has the overall appearance of techniques can still be employed. Using the process condi roast and ground coffee, has been cell distorted as that term is tions specified herein gives a product having the bulk density used herein. The distortion that occurs results in from 20 to of roast and ground coffee. 65% of the cells being at least partially disrupted and there 0441. In producing light-milled roast and ground coffee, fore extractability of the product is increased. the light-milled, cell-fractured coffee product moisture con 0444 The diameter of the roll mills employed controls the tent preferably should be from 2.5 to 7.0 percent by weight, angle of entry into the nip. Angle of entry into the nip in turn with from 3.0 to 6.0 percent being most preferred. Conse has a direct effect on the particle size of the coffee that will quently, the moisture content of the conventional roast and pass through the nip, and consequently on the bulk density of ground coffee particles which are utilized to prepare light the resultant light-milled coffee. To produce the hereinbefore milled coffee preferably should be within the range of from described light-milled coffee, with the requisite bulk density 2.5 to 7.0%. At moisture contents less than 2.5% the conven which is within the range of bulk densities for roast and tional roast and ground coffee is often too dry to produce ground coffee, it is preferred that the roll diameter be within light-milled coffee, and may have a tendency to grind into the range of 6 inches to 30 inches with from 9 inches to 25 fines rather than become light-milled. On the other hand, inches being most preferred. If rolls having a diameter of less moisture contents above 7.0% preferably are to be avoided than 6 inches are utilized the roast and ground coffee particles because the Staling propensity of the resulting light-milled with a normal particle size distribution as hereinbefore coffee is Substantially increased at Such high moisture con described often tend to churn on the mill Surfaces and not pass tents. Providing a moisture content of the conventional roast through the nip; consequently, the throughput rate of the and ground coffee to be light-milled within the range of from conventional roast and ground coffee employed to produce 3.0 to 6.0% provides the highest yield of light-milled coffee light-milled coffee is so slow as to be impractical. Roll mills coupled with little or no flavor degradation, and is most there having roll diameters greater than 30 inches are not readily fore preferred. available. 0442. In regard to the particle size of the conventional 0445. As can be seen from the foregoing description of the roast and ground coffee employed in producing the light fifth group of embodiments, the ranges of each of the milled product of the fifth group of embodiments, no critical described milling process variables are closely tied to and US 2014/0370181 A1 Dec. 18, 2014 27 correlated with each of the other processing variables. A characterization phases, see Sivetz, Coffee Processing Tech change in one variable often has a direct effect in changing nology, Vol. 1, published in 1963 by Avi Publishing Com another variable. pany, at pages 173 through 175. 0446. In preparing the coffee composition for use in a 0450 Consumer-acceptable roast and ground coffees gen beverage unit as defined in the Summary of the Invention, the erally comprise a blend of all three classes of coffees. Blend coffee in the coffee composition 110/130 and beverage mate ing is utilized to emphasize the desirable characteristics of rial 120 as shown in FIGS. 1A, 1B, and 1C may have various each grade of coffees. For example, some strong body notes cell structures. As previously mentioned, the invention con characteristic of low grade coffees are desirable as well as templates flaked roast and ground coffee. Flaking of roastand Some fragrant and aromatic notes characteristic of high grown ground coffee can be used advantageously to control or regu coffees. Intermediate grade quality coffees typically contrib late the flavorand aroma of coffee as well as the extractability. ute to overall taste impact and body of the coffee. Because the In the sixth group of embodiments according to the present most desirable flavor and aromas obtainable in roast and invention, an improved roast coffee product comprising as a ground coffee blends come from high grown coffees, it is major portion low and/or intermediate grade flaked coffees, desirable to include high percentages of high grown coffees in and as a minor portion high-grade roasted and ground coffee, roastand ground coffeeblends. However, high grown coffees, is prepared by utilizing the varying effect of flaking on high, as one might expect, are the most expensive of the three low, and intermediate grade coffees. Also disclosed in the classes of coffees; and moreover, high grown flavor not sixth group of embodiments are flakes having particularly complemented by other flavors is not desirable. desirable physical properties. 0451. In regard to the blends of coffees presently sold in 0447 The sixth group of embodiments relates to an the market, it should be remembered that each of the roastand improved roast coffee product characterized by enhanced ground coffee products presently sold are characterized as extractability and a predominance of the delicate flavor and being ground particles prepared from roasted whole coffee aroma characteristics of high quality coffee, said product beans. These particles are substantially intact in cellular utilizing, in predominating proportions, flaked coffee of inter structure and are not compressed to provide Substantial cel mediate and/or low quality varieties. lular disruption. 0448 Briefly and generally, the objects and advantages of 0452. As used in the sixth group of embodiments, the term the sixth group of embodiments are accomplished by com “roast and ground coffee' refers to a coffee product compris pressing roast and ground coffee selected from a class con ing conventionally prepared roast and ground coffee particles sisting of the low and intermediate grade coffees into the form often characterized herein as non-compressed coffee par of flakes to diminish the undesirable flavor and aroma con ticles. It does not include flaked roast and ground coffee stituents and bring out the more desirable of such constituents particles which are hereinafter referred to as “flaked coffee’; naturally present in Such coffees thereby enhancing their the term "roast and ground encompasses both caffeinated flavor and aroma properties from a consumer acceptance and decaffeinated versions, unless otherwise stated. standpoint while simultaneously increasing their extractabil 0453 While the presently marketed roast and ground cof ity, and thereafter admixing such coffee flakes with lesser fee products do enjoy a Substantial part of the coffee market, amounts of non-compressed roast and ground particles of the they have several disadvantages. One of the primary disad more expensive high grade coffees whose natural flavor and Vantages is that conventional roast and ground coffee prod aroma properties are substantially unimpaired. Preferably, ucts have poor extractability. That is, during preparation of the resultant coffee product comprises from 70 to 90 percent cups of roast and ground coffee beverage, it has been shown by weight of a blend of low and intermediate quality coffee that only about 20 percent of the solid material contained in flakes. More preferably, the low and intermediate quality the roast and ground coffee is extracted during conventional coffee flakes comprise 75 to 85 percent by weight of the percolation processes. The remaining portion of the coffee is coffee product, and the weight ratio of low to intermediate discarded as grounds. The poor extractability either results in quality flakes is from 0.1:1 to 3:1. a weakened beverage or in excessive brewing time; in order to 0449 In connection to the background of the sixth group compensate for low extractability consumers usually increase of embodiments, roast and ground coffee products presently the amount of coffee used to make a cup which increases available in the market place comprise various blends of expense to the consumer. differing grades of coffees. The differing grades of coffees are 0454. Flaked coffee is known in the art. McKinnis, U.S. classified in the art as “low,” “intermediate.” and “high.” Pat. No. 1,903,362, Rosenthal, U.S. Pat. No. 2,123,207, and These terms, i.e. low, intermediate, and high, define three Carter, U.S. Pat. No. 2.368,113, all disclose preparation of distinct classes of coffees, each having its own characteristic flaked coffee by roll milling roast and ground coffee. Of these properties. For example, in regard to natural flavor and aroma, three patents, the most relevant is McKinnis who discloses low grade coffees such as Robustas and others enumerated production of “very thin' and “substantially uniform thick hereinafter are often characterized as “dirty.” “earthy.” “rub ness' coffee flakes by roll milling roast and ground coffee bery,” “fermented.” “musty,” and “strong, pungent and bitter.” particles. Intermediate grade coffees such as Brazilian coffees, African 0455 While each of the above-cited patents discloses naturals and others detailed hereinafter, are characterized in broadly the concept of flaking roast and ground coffee to terms of natural flavorand aroma as “bland,” “neutral,” “lack increase extractability, none of the cited patents disclose flak ing in aromatic and high grown notes.” “sweet, and “not ing of roast and ground coffee as a means of regulating coffee offensive.’ High grown coffee Such as good quality Arabicas flavor and aroma. Therefore, while increasing extractability is and Colombians, are characterized in terms of natural flavor taught by these three prior art patents, the effect of flaking on and aroma as having “excellent body.” “acid.” “fragrant.” coffee flavor and aroma is not taught by the prior art, and “thin,” “aromatic.” and occasionally "chocolatey. For details actually the prior art teaches away from this concept. The in regard to definitions of these natural flavor and aroma essence of the sixth group of embodiments lies in the discov US 2014/0370181 A1 Dec. 18, 2014 28 ery that flaking can be utilized as an effective process tool in to intermediate quality flakes is within the range of from 0.1 regulating coffee flavor and aroma and in producing coffee to 1 to 3 to 1. Such improved roast coffee product may products comprising as a major portion flaked intermediate comprise flaked roast and ground coffee and roast and ground and/or low grade coffees, and as a minor portion high grade coffee particles wherein said roast and ground coffee particles roast and ground coffee. comprise from 10 percent to 30 percent by weight of said 0456. In sixth group of embodiments, flaking of roast and product. From 3 to 10 percent of said product may pass ground coffee not only has an effect on the property of through a 40 mesh U.S. Standard screen and wherein not extractability, it also can have a very definite effect on flavor more than 35 percent of said product will remain on a 12 mesh and aroma. Even more Surprisingly, the effect of flaking on U.S. Standard screen. The roast and ground coffee particles flavor and aroma varies widely depending on the grade of may comprise from 15 to 25 percent by weight of the product. coffee involved, and that flaking can be used selectively to The flaked roast and ground coffee may have a flake thickness advantageously regulate coffee flavor and aroma to produce of from 0.008 inch to 0.25 inch, such as from 0.010 inch to an improved coffee product in accord with the objects of sixth 0.016 inch. group of embodiments. The sixth group of embodiments 0466. In more specific examples under this aspect, the resides in the selective utilization of this heretofore unknown improved roast coffee product may comprise flaked roast and aspect of flaking as an effective process tool to produce ground coffee and roast and ground coffee particles wherein improved novel coffee products comprising unique mixtures said roast and ground coffee particles comprise from 10 to 30 of the different grades of coffees. percent by weight of said product. For instance, from 3 to 10 0457. It is the object of the sixth group of embodiments to percent of said product will pass through a 40 mesh U.S. regulate and control the flavor strength and aroma of coffee by Standard screen and wherein not more than 35 percent of said providing a coffee product comprising as a major portion product will remain on a 12 mesh U.S. Standard screen. The flaked coffee particles, said flakes being of low and/or inter roast and ground coffee particles may comprise from 15 to 25 mediate quality, and as a minor portion roast and ground percent by weight of said product. The flaked roast and coffee particles, said roastand ground coffee comprising high ground coffee has a flake thickness of from 0.010 inch to grade coffees. 0.016 inch. 0458 An additional object of the sixth group of embodi 0467. In more specific examples under this aspect, the ments is to provide roast and ground coffee flakes having flaked roast and ground coffee has a flake thickness of 0.008 unique physical characteristics suitable for providing a com inch to 0.25 inch; and/or a flake bulk density of from 0.38 mercially attractive coffee product. g/cc. to 0.50 g.?cc. 0459. An additional object of the sixth group of embodi 0468. In more specific examples under this aspect, the ments is to provide a process of making a coffee product coffee flakes may comprise low grade Robusta coffees and comprising as a major portion flaked roast and ground coffee, said non-compressed coffee particles comprise high grade said coffees being of intermediate and/or low grade coffees, Arabica coffees. and as a minorportion, roast and ground coffee particles, said 0469. In more specific examples under this aspect, the particles being of high grade coffee varieties. coffee flakes may comprise intermediate grade Brazilian cof 0460. One aspect of the sixth group of embodiments pro fees and said non-compressed coffee particles comprise high vides for a coffee composition for use in a beverage unit Such grade Arabica coffees. as a cartridge and method thereofas defined in the Summary 0470. In more specific examples under this aspect, the of the Invention, wherein the coffee composition comprises coffee flakes may comprise low grade Robustas and interme an improved roast coffee product of enhanced extractability, diate grade Brazilian coffees, and in which said non-com flavor and aroma characterized by predominance of the deli pressed coffee particles comprise high grade Arabica coffees. cate flavor and aroma notes naturally characteristic solely of 0471. In more specific examples under this aspect, the high grade coffees comprising: flakes may be made from coffee selected from the class con 0461 a. as a minor portion thereof, non-compressed, high sisting of Robustas, low grade Naturals, low grade Brazils, grade roast and ground coffee particles of unimpaired natural low grade unwashed Arabicas, intermediate Brazils, African flavor and aroma; and Naturals, others free from strong Rioy flavors and combina 0462 b. as a majorportion thereof, roast and ground coffee tions thereof, and in which the non-compressed high grade selected from a class of coffee consisting of the low and roast and ground coffee particles are made from coffees intermediate grade coffees, said low and intermediate grade selected from the class consisting of high grade Arabicas and coffees being in the form of compressed flakes wherein the combinations thereof. Said low grade Naturals may comprise undesirable natural flavor and aroma constituents thereof Haiti XXX, Peru Naturals, and Current Salvadors, said low have been diminished and the extractability thereof grade unwashed Arabicas comprise Ugandas, Indonesians, enhanced. Ivory Coast, Dominican Republics, Ecuador Resacas, and 0463. In more specific examples under this aspect, the Guatemalan TEMs, said intermediate grade Brazils com majorportion of the improved roast coffee product comprises prise Santos and Paranas, and said other coffees free from low quality coffees. strong Rioy flavors comprise good quality Sul de Minas; and 0464. In more specific examples under this aspect, the said high grade Arabicas comprise Colombians, Mexicans, majorportion of the improved roast coffee product comprises and other washed Milds such as strictly hard bean Guatema intermediate quality coffees. lans. 0465. In more specific examples under this aspect, the 0472. In more specific examples under this aspect, the majorportion of the improved roast coffee product comprises compressed coffee flakes may have a Substantial portion of a blend of low and intermediate quality coffees. Such flaked their cells disrupted. For instance, the compressed coffee roast and ground coffee may have a flake bulk density of from flakes may have at least from about 70 to about 85 percent of 0.38 g/cc to 0.50 g/cc. The weight ratio of low quality flakes their coffee cells disrupted. US 2014/0370181 A1 Dec. 18, 2014 29
0473. Another aspect of the sixth group of embodiments 0484 Still another aspect of the sixth group of embodi provides for a coffee composition for use in a beverage unit ments provides for a coffee composition for use in a beverage and method thereofas defined in the Summary of the Inven unit and method thereof as defined in the Summary of the tion, wherein the coffee composition comprises an improved Invention, wherein the coffee composition comprises an roast coffee product characterized by enhanced extractability improved roast coffee product characterized by enhanced and a predominance of the delicate flavor and aroma charac extractability and a predominance of the delicate flavor and teristics of high quality coffee utilizing in predominating aroma characteristics of high quality coffee utilizing in pre proportions flaked roast and ground coffee of low and inter dominating proportions flaked roast and ground coffee of mediate quality varieties, made from a method comprising: intermediate quality varieties, made from a method compris 0474 a. roasting and grinding into particles low quality 1ng: coffees and thereafter substantially enhancing the extractabil 0485 a. roasting and grinding into particles intermediate ity of said coffee particles while simultaneously substantially quality coffees and thereafter Substantially enhancing the reducing their natural Volatile flavor constituents by expelling extractability of said coffee particles while simultaneously a Substantial portion of the natural flavor-producing constitu decreasing their aroma and increasing their natural flavor ents normally entrapped therein by compressing said coffee producing capability by expelling a Substantial portion of the particles into flakes; natural gases normally entrapped therein by compressing said 0475 b. roasting and grinding into particles intermediate coffee particles into flakes; quality coffees and thereafter Substantially enhancing the 0486 b. roasting and grinding coffee of the high quality extractability of said coffee particles while simultaneously variety to form non-compressed coffee particles of unim decreasing their aroma and increasing their natural flavor paired flavor and aroma; and producing capacity by expelling a Substantial portion of the 0487 c. admixing said intermediate quality coffee flakes natural gases normally entrapped therein by compressing said in predominating proportions with said high quality coffee coffee particles into flakes; particles to form a highly extractable coffee product of prime 0476 c. roasting and grinding coffee of the high quality quality flavor and aroma. variety to form non-compressed coffee particles of unim 0488. In more specific examples under this aspect, said paired flavor and aroma; and flakes may have at least from about 70 to about 85 percent of 0477 d. admixing said low and intermediate quality cof their coffee cells disrupted, e.g. at least from about 70 to about fee flakes in predominating proportions with said high quality 85 percent of their coffee cells disrupted. coffee particles to form a highly extractable coffee product of 0489. A further aspect of the sixth group of embodiments prime quality flavor and aroma. provides a coffee composition for use in a beverage unit and 0478. In more specific examples under this aspect, steps method thereofas defined in the Summary of the Invention, (a) and (b) may be conducted simultaneously by using a blend wherein the coffee composition comprises a roast and ground of low and intermediate quality coffees. The flakes may have coffee flakes having a flake bulk density of from 0.38 g/cc. to a Substantial portion of their coffee cells disrupted, e.g. at 0.50 g/cc. a flake thickness of from 0.008 inch to 0.025 inch least from about 70 to about 85 percent of their coffee cells and a flake moisture content from 2.5 to 7.0 percent. disrupted. 0490. In more specific examples under this aspect, the roast and ground coffee flakes may be caffeinated; the bulk 0479. Still another aspect of the sixth group of embodi density may be from 0.42 g/cc. to 0.48 g/cc; the coffee flakes ments provides for a coffee composition for use in a beverage may have a flake thickness of from 0.010 inch to 0.016 inch; unit and method thereof as defined in the Summary of the the coffee flakes may have a flake moisture content of from Invention, wherein the coffee composition comprises an 3.0 to 6.0 percent; the coffee flakes may have a color on the improved roast coffee product characterized by enhanced Hunter Color “L” scale of from 18 to 23, such as from 19 to extractability and a predominance of the delicate flavor and 21; the coffee flakes may be further characterized as low aroma characteristics of high quality coffee utilizing in pre grade and/or intermediate grade coffee flakes; they may be dominating proportions flaked roast and ground coffee of low Robusta coffee flakes; from 3 to 10 percent of said flakes may quality variety, made from a method comprising: pass through a 40 mesh U.S. Standard Screen, e.g. not more 0480 a. roasting and grinding into particles low quality than 35 percent of said flakes will remain on a 12 mesh U.S. coffees and thereafter substantially enhancing the extractabil Standard screen; and/or the coffee flakes may be decaffein ity of said coffee particles while simultaneously substantially ated coffee flakes. reducing their natural Volatile flavor constituents by expelling 0491. The sixth group of embodiments as described above a Substantial portion of the natural flavor-producing constitu will be further described in the following, and exemplified by ents normally entrapped therein by compressing said coffee Examples 21-25. particles into flakes; 0492. The essence of the sixth group of embodiments lies 0481 b. roasting and grinding coffee of the high quality in the discovery that flaking of roast and ground coffee par variety to form non-compressed coffee particles of unim ticles can be used as an effective tool to modify flavor and paired flavor and aroma; and aroma characteristics of various grades of coffees. 0482 c. admixing said low quality coffee flakes in pre 0493 As used in the sixth group of embodiments, “natural dominating proportions with said high quality coffee par flavor and aroma’ refers to the flavor and aroma of conven ticles to form a highly extractable coffee product of prime tional roast and ground coffees; the phrase “flavorand aroma' quality flavor and aroma. perse refers to the flavor and aroma result achieved by com 0483. In more specific examples under this aspect, the pressing roast and ground coffee into flakes. flakes may have a substantial portion of their coffee cells 0494 The effect of flaking of roast and ground coffee disrupted, such as at least from about 70 to about 85 percent particles varies with the grade of roast and ground coffee of their coffee cells disrupted. particles to be flaked. For example, flaking of low grade US 2014/0370181 A1 Dec. 18, 2014 30 coffees increases the strength of coffee beverages produced are "milds often referred to as high grade Arabicas, and therefrom and also enhances the flavor and aroma of the low include, among others, Colombians, Mexicans, and other grade coffees by expelling natural Volatile flavor constituents washed milds, such as strictly hard bean Costa Ricans, Ken producing the bitter, rubbery-tasting notes which characterize yas A and Bs, and strictly hard bean Guatemalans. these coffees. Conversely, when high grade coffees are flaked, 0500. It is believed that, utilizing the above-described while there is an increase in beverage strength, there is a effects of flaking on coffee flavor and aroma, an improved decrease in favorable natural flavor and aroma qualities. roast coffee product can be prepared. The improved roast When intermediate grade quality coffees are flaked, there is a coffee product of the sixth group of embodiments is superior slight decrease in aroma, an increase in strength and an to products comprising all roastand ground coffee particles in increase in those natural flavors which are regarded as typi that it has increased extractability, greater flavor Strength, and cally characteristic of intermediate grade coffees. The effect an aroma equal to that of conventional roast and ground of flaking on each of these coffees will now be discussed in coffee products. The improved roast coffee product of the detail. sixth group of embodiments is superior to a 100 percent 0495 First in regard to low grade coffees, flaking of low flaked coffee product in that it has a superior flavor and aroma. grade coffees increases the strength of the resulting coffee 0501. In its broadest aspect, the improved roast coffee beverage and enhances the flavor and aroma of a resulting product of the sixth group of embodiments comprises as a coffee beverage. major portion low and/or intermediate quality coffee flakes, 0496 Generally speaking, low quality coffees such as and as a minor portion high grade coffee grounds. Robustas, produce brews with strong distinctive natural flavor 0502. It is preferred that the majorportion of the improved characteristics often noted as bitter and possessing varying coffee product of the sixth group of embodiments, i.e., the degrees of a rubbery flavor note, which are not considered flake portion, be comprised of a blend of low quality and desirable in large quantities in united States coffee products. intermediate quality coffee flakes. However, if desired, all However, it has been Surprisingly discovered that producing low quality coffee flakes or all intermediate quality coffee flaked low quality coffees enhances the flavor and aroma of flakes can be utilized. Of course, because flaking affects the the low quality coffee coupled with an increase in strength. In flavor and aroma of low quality coffees and intermediate other words, the natural bitterness and rubber note usually quality coffees in a different manner, utilization of all one characteristic of low quality coffees becomes much less grade to the exclusion of the other will provide a product of dominant when the low quality coffee is a flaked low quality differing flavor and aroma. In the preferred embodiment of coffee. utilizing a blend of low and intermediate quality flakes, it is 0497. This phenomenon, i.e., increase in strength coupled preferred that the weight ratio of low to intermediate quality with an enhancement in flavor and aroma, is seen in low flakes be within the range of from 0.1:1 to 3:1, and most quality coffees such as Robustas, low grade naturals such as preferably within the range of 0.5:1 to 2:1. Preferably the low Haiti XXX, Peru naturals, current Salvadors, low grade Bra grade and intermediate grade coffees are blended and then Zils, and low grade unwashed Arabicas such as Ugandas, flaked simultaneously; however, they can also be flaked indi Indonesians, Ivory Coast, Dominican Republics, Ecuador vidually and subsequently blended. Resacas, and Guatemalan TEMs. 0503 Suitable high grade coffees for the roast and ground 0498 Turning now to intermediate grade quality coffees, coffee minor portion of the improved roast coffee product of when intermediate quality coffees are flaked, the resulting the sixth group of embodiments, and suitable low and inter flaked coffee is characterized by an increase in strength, a mediate quality coffees for the major flake portion of the slight loss of natural aroma, and an increase in those natural improved roast coffee product of the sixth group of embodi flavors which are regarded as typically characteristic of inter ments have been previously set forth in this specification. mediate grade coffees. In other words, flaked intermediate 0504. In a most preferred aspect of the sixth group of grade coffee exhibits an increase in extractability, a slight embodiments, the improved roast coffee product comprises a decrease in natural aroma, and Surprisingly, an increase in the mixture of flaked roast and ground coffee with roast and typical, i.e. natural, flavor characteristics usually associated ground coffee particles wherein the roast and ground coffee with the specific coffee involved. For example when interme particles comprise from 10 percent to 30 percent by weight of diate grade Brazilian coffees are flaked, there is an increase in said product, said roast and ground coffee particles being of extractability, a slight loss of natural Brazilian aroma, and high grade variety, and said flaked roast and ground coffee Surprisingly, an increase in the typical flavor of Brazilian being of low and/or intermediate quality coffees. coffees. This phenomenon, i.e., increase in extractability, 0505. The principal advantages of producing a product slight loss of aroma, and increase in characteristic and/or comprising as a majorportion thereof flaked roast and ground natural flavor, is seen in flaked intermediate grade coffees. coffee are three-fold. Suitable intermediate grade coffees for flaking are Brazilian 0506 First, the modification in flavor strength and aroma coffees such as Santos and Paranas, African naturals, and capable of being achieved by utilization of flaked coffee others free from strong Rioy flavors such as good quality Sul allows greater control over ultimate product flavor and aroma de Minas. as well as blend variation in producing the product. 0499 Turning now to the effect of flaking on high grade 0507. The second principal advantage of a product com coffees, when high grade coffees are flaked the resulting prising as a major portion thereof, flaked roast and ground coffee is increased in strength, i.e., extractability, and there is coffee, is that the product provides a brew of increased a substantial decrease in both natural flavor and aroma. For strength. As mentioned previously in the sixth group of example, when high grade Arabicas such as Colombians are embodiments, flaked roast and ground coffee provides flaked, there is a decrease in natural flavor and aroma of the increased extractability and therefore increases brew resulting flaked high grade Colombian, coupled with an strength; consequently, the improved roast coffee product of increase in strength. Examples of typical high quality coffees the sixth group of embodiments because a major portion of US 2014/0370181 A1 Dec. 18, 2014 said product is flaked roast and ground coffee, provides a Department of Commerce (see Coffee Brewing Workshop product of Substantially increased beverage strength. Manual, page 33, published by the Coffee Brewing Center of 0508. Third, disruption of the cellular structure of coffee the Pan American Coffee Bureau) are as follows: “Regular during milling to compress into flakes provides an easy means grind, 33 percent is retained on a 14 mesh Tyler standard of escape for gases contained in coffee cells. Degassing is sieve, 55 percent is retained on a 28 mesh Tyler standard sieve highly advantageous in that in Subsequent packaging com and 12 percent passes through a 28 mesh Tyler standard sieve; pensation for slow gas evolution need not be made. For “drip grind 7 percent is retained on a 14 mesh Tyler standard instance, many roast and ground coffees presently sold on the sieve, 73 percent on a 28 mesh Tyler standard sieve and 27 market are vacuum packed in strong metal containers. percent passes through a 28 mesh Tyler standard sieve; and Vacuum packing is employed as a means of providing a “fine grind, 100 percent passes through a 14 mesh Tyler reduction in the internal container pressure, the buildup of sieve, 70 percent being retained on a 28 mesh Tyler standard which is caused by gases evolving from coffee cells. Thus, sieve and 30 percent passing through a 28 mesh Tyler stan slow gas evolution from coffee cells can necessitate the dard sieve. Of the above mentioned grind sizes, the most employment of an expensive vacuum packing procedure. It preferred is regular grind. also can necessitate the utilization of strong metal containers. 0514. In making the flaked roast and ground coffee to be The strong metal containers are employed to prevent internal utilized in the sixth group of embodiments, it is preferred that pressure from bulging the container. Providing a substantially grind sizes finer than fine grind not be employed. For degassed flaked roast and ground coffee product avoids the example, when Espresso grind is utilized a high incidence of need for a vacuum packing procedure and for utilizing expen fine coffee particles is found to exist after the roll milling sive strong metal containers. The improved roast coffee prod operation which is utilized in producing flaked coffee; this uct disclosed herein can be packed in foil fiber containers or high incidence offine coffee particles has the disadvantage of in thinner andless expensive metal containers and need not be producing unsightly coffee dust which is often associated vacuum packed. with high percentages of fines. However, a certain Small per 0509. One disadvantage of flaked roast and ground coffee centage of fines present in the improved roast coffee product perse, with the exception of flaked low quality coffees, is the of the sixth group of embodiments has been found to be lack of desirable aroma and volatile constituents. Providing a desirable. More specifically, in providing a consumer accept product with pleasing aroma and flavor-laden Volatile con able product it is preferred that the improved roast coffee stituents is essential if high consumer acceptance is to be product, i.e., the flakes and grounds mixture, have Suitable obtained. particle dimensions such that from 3 to 10 percent of said 0510 Admixing roast and ground coffee particles with product will pass through a 40 mesh U.S. Standard screen and flaked roast and ground coffee within the most preferred not more than 35 percent will remain on a 12 mesh U.S. range of from 10 percent to 30 percent by weight of roast and Standard screen. It is believed that if less than 3 percent of the ground coffee particles overcomes the disadvantage of flaked improved roast coffee product passes through a 40 mesh roast and ground coffee and yet retains the principal advan screen, the liquid flow through a percolator basket containing tages of flaked roast and ground coffee. said product becomes too rapid and insufficient contact time 0511. As mentioned previously in the sixth group of of the extraction liquid and the flaked coffee portion of the embodiments, it is preferred that the mixture of flaked roast coffee product will result in a weakening of the brew strength. and ground coffee and roast and ground coffee particles con On the other hand, if more than 10 percent of the improved sist of from 10 percent to 30 percent by weight of roast and coffee product passes through a 40 mesh screen the high ground coffee particles. If less than 10 percent by weight of incidence of very fine particles may tend to produce a con roast and ground coffee particles is utilized the product may Sumer-undesirable"floatbrew” and also increases the amount not have a significant increase in aroma quality. On the other of pot sediment. A float brew refers to a condition in a perco hand, ifamounts of roast and ground coffee particles Substan lator basket wherein the basket holes become plugged. This tially in excess of 30 percent by weight are utilized the advan may cause a buildup of liquid in the basket and floating of tages of utilizing flakes of roast and ground coffee in the coffee particles to the top of the basket. The result may be a mixture may be substantially decreased, i.e., the Substantial weak brew due to under extraction. Additionally, it is believed increase in brew strength coupled with flavor changes may that if more than 35 percent of the improved roast coffee not occur to a significantly noticeable degree. To obtain the product is of particle dimensions such that it remains on a 12 advantages of flaked roast and ground coffee and yet maintain mesh U.S. Standard screen, consumer preference for the a product of high aroma and flavor, especially good results are product is Substantially decreased. achieved when the roast and ground coffee particles comprise 0515. As previously mentioned, a preferred embodiment from 15 percent to 25 percent by weight of the mixture. of the sixth group of embodiments provides a flavor-en 0512. Of course, as explained with respect to the broader hanced product of high consumer preference. This preferred description of the sixth group of embodiments, as long as the embodiment comprises producing flaked coffee from a blend flaked coffee is a major portion (i.e., greater than 50 percent) of low and intermediate quality coffees and admixing there and the roast and ground coffee a minor portion (i.e. less than with, within the prescribed ranges, roast and ground coffee 50 percent), an improved roast coffee product is still pro particles produced from high quality coffees. duced. Thus, the above narrower weight percentages are 0516. In this preferred embodiment, the flakes of roast and given with reference to highly preferred embodiments. ground coffee are prepared from coffee beans such as those 0513. In regard to the particle size of the roast and ground listed above under the intermediate and low quality catego coffee employed in the flaking process, it is preferred that the ries coffee be regular, drip, or fine grind as these terms are used in 0517. The coffees to be utilized in forming the roast and a traditional sense. The standards of these grinds as Suggested ground coffee particles are those listed above under high in the 1948 Simplified Practice Recommendation by the U.S. quality coffee beans and can be generically described as US 2014/0370181 A1 Dec. 18, 2014 32
"milds.” It is within the scope of the sixth group of embodi to break up and form fines and unsightly coffee dust. Espe ments that various blends of high quality coffees Such as a cially desirable and Suitable mixing devices are revolving blend of Mexicans and Colombians, for example, can be “horizontal plane baffle mixers such as a common cement employed in producing high quality roast and ground coffee mixer; however, the most preferred blenders are falling chute particles. riffle blenders. 0518. A principal advantage of producing the improved 0522. A falling chute riffle blender is comprised of a large roast coffee product of the sixth group of embodiments from cylindrical tube-like vessel with downwardly angled baffles low and intermediate quality coffee beans in regard to the mounted on the inside walls thereof. To promote gentle tum roast and ground flakes and high quality coffee beans in bling and intermixing the roast and ground coffee particles regard to the roast and ground coffee particles is that a Sub and flaked roast and ground coffee to be admixed are gravity stantial flavor and aroma enhancement is noted. While not fed through the baffled vessel. As the flakes and grounds wishing to be bound by any theory it is believed that the tumble down they hit each baffle and, because the baffles are explanation for this is as follows: The roll milling process, mounted in a downward angle, slide off and fall down onto hereinafter explained, utilized to produce flaked roast and baffles mounted in lower positions. By the time the flakes and ground coffee disrupts the cellular structure of the coffee grounds reach the bottom they have become (more or less) particles and allows for easy exiting of gases contained within uniformly admixed. At the bottom of the vessel the mixture the coffee cells. While this is advantageous in that a degassed can be drawn off into a vessel or can be carried away on a coffee product is produced. Some of the escaping constitu conveyor belt for easy packaging. ents, such as delicate aroma and Volatile constituents, are 0523 To insure uniform intermixing within the preferred desirable. Thus, flaking especially of high quality coffees, range of from 10 to 30 percent by weight of roast and ground may involve a loss of prime quality coffee flavor notes. On the coffee particles, the roast and ground coffee particles and the other hand, flaking of roast and ground coffee particles flaked roast and ground coffee are gravity fed into the top of greatly increases the Surface area of the particles and conse the falling chute rifle blender at flow rates calculated to give quently when brewed, flakes produce a strong flavored coffee mixtures within the prescribed range. For instance, if a mix with excellent body. In regard to roast and ground coffee ture comprising 20 percent roast and ground coffee particles particles produced from high-quality coffee beans, these is desired, roast and ground coffee particles can be fed into the ground particles are flavor laden with delicate, natural, prime falling chute riffle blender at a rate of 900 lbs./hr. and flaked aroma and flavor constituents. Thus, any admixture of these roast and ground coffee particles can be fed into the blender at two components produces a substantially degassed product a rate of 3600 lbs./hr. which has a strong body flavor and which is additionally 0524. While flaking of roast and ground coffee offers sev characterized by having delicate prime flavorand aroma char eral advantages, all enumerated above, flaking of roast and acteristics present even though a Substantial portion of the ground coffee also produces a disadvantage in regard to pack coffee in the novel product has been flaked. aging of the product. This is the tendency of flaked roast and 0519 In forming flakes of roast and ground coffee par ground coffee to vary in bulk density from the bulk density ticles to be utilized in the coffee product, the roast and ground and/or “tamped bulk density, the two being used inter coffee is Subjected to a mechanical compressing pressure by changeably (in the sixth group of embodiments), of roast and passing roast and ground coffee through two parallel Smooth ground coffee. As used these terms herein refer to the overall or highly polished rolls So that the coffee particles passing density of a plurality of particles measured after vibratory between the rolls are crushed and flattened such that the settlement in a manner Such as that described on pages 130 coffee cellular structure is disrupted and the resulting appear and 131 of Sivetz, "Coffee Processing Technology. Avi Pub ance is that of a flake. Smooth or highly polished rolls are lishing Company, Westport, Conn., 1963, Volume II. It is desirable because these rolls are easy to clean. Other rolls can believed that flaked roast and ground coffee having a certain be used if the desired flaking of roast and ground coffee range of thicknesses, elaborated in detail below, will not particles can be obtained. The flakes are formed in integral change their bulk density after packaging and handling. units, are moderately firm and can be easily handled. If 0525) More specifically, providing roast and ground cof desired, the flaked roast and ground coffee can also be passed fee flakes having a bulk density of from 0.38 g/cc. to 0.50 through a series of roll mills but in the preferred embodiment g.fcc. is important if consumer acceptance is desired. This is for forming flaked roast and ground coffee to be utilized in the so because bulk densities within this range are generally the product of the sixth group of embodiments passage of the bulk densities of conventionally prepared roast and ground roast and ground coffee particles through two parallel rolls is coffees of “regular,” “drip’ and “fine grind. If the bulk den used. sity varies from this range and is for example higher, the 0520. The flaking operation results in the roast and ground consumer would need to use a substantially lesser than usual coffee particles being crushed and dropped from the rolls in quantity of coffee to produce a brew of given strength; this the form of flakes. The roll milling can be accomplished in required adjustment in consumer habits might be made with any of the well-known and commercially available roll mills some difficulty. Such as those sold under the trademarks of Lehmann, Thropp, 0526. A preferred roast and ground coffee flakes bulk den Farrell and Lahoff. sity is from 0.42 g/cc. to 0.48g.fcc. However, providing roast 0521. The process of mixing flaked roast and ground cof and ground coffee flakes having a bulk density within the fee and roast and ground coffee particles within the pre previously referred to broader range or the preferred narrower scribed ranges to form the improved roast coffee product of range of from 0.42 g/cc. to 0.48g.fcc. is not an easy accom the sixth group of embodiments is not critical. Any Suitable plishment because the physical characteristics of thin flaked method of admixing which does not involve shear mixing can coffee are such that a propensity for variegated product bulk be employed. Shear mixing is unsuitable because shear mixes density exists. This is so because upon packing in a container cold work the flakes of roast and ground coffee causing them flaked coffee has a tendency for the flakes to align themselves US 2014/0370181 A1 Dec. 18, 2014 in parallel planes producing a very compact product with a 0531. In providing a consumer acceptable flaked coffee bulk density Substantially higher than that of roast and ground product it is preferred that the flaked coffee have a color coffees presently marketed. Moreover, the parallel plane which is defined by a Hunter Color “L” scale value ranging alignment, which takes place primarily after packing, from 18 to 23, with from 19 to 21 being most preferred. increases the container outage. In other words, the space Flaked coffee Hunter Colors within these ranges have been between the upper surface of the product and the upper sur found to be desirable because within these ranges the flaked face of the container is increased due to settling of the flaked product has a color impression Substantially equal to that of product. Large container outages are not appreciated by the roast and ground coffee, which the consumer regards as consumer. Additionally, the higher tamped bulk density highly desirable. would necessitate an adjustment in consumer habits of Volu 0532. The Hunter Color scale values, utilized herein to metric measurement. define a preferred color of a flaked coffee product, are units of 0527 Flaked coffee generally has a flake thickness of from color measurement in the Hunter Color system. That system 0.001 inch to 0.030 inch. Thin flakes (i.e. 0.001 inch to 0.007 is a well-known means of defining the color of a given mate inch) are undesirable because of their cellophanelike appear rial. A complete technical description of the system can be ance and fragile nature; on the other hand, Very thick flakes found in an article by R. S. Hunter, “Photoelectric Color (i.e. 0.026 inch to 0.030 inch) are undesirable because of their Difference Meter.” Journal of the Optical Society of America, high flake density. Flakes of intermediate thickness, (i.e. from Vol. 48, pp.985-95, 1958. Devices specifically designed for 0.008 inch to 0.025 inch) have been found especially desir the measurement of color on the Hunter scales are described able for a number of reasons, enumerated below. in U.S. Pat. No. 3,003,388 to Hunter et al., issued Oct. 10, 1961. In general, Hunter Color “L” scale values are units of 0528. To produce roast and ground coffee flakes having light reflectance measurement, and the higher the value is, the the requisite bulk density as previously discussed, and which lighter the color is since a lighter colored material reflects do not have a propensity towards changing bulk density after more light. In particular in the Hunter Color system the “L” packing, it is important that the flaked coffee have a flake scale contains 100 equal units of division; absolute black is at thickness of from 0.008 inch to 0.025 inch and preferably the bottom of the scale (L=0) and absolute white is at the top from 0.010 inch to 0.016 inch. Flaked coffee having a flake of the scale (L=100). Thus in measuring Hunter Color values thickness within the above referred to broader range and of the flaked coffee of the sixth group of embodiments, the especially within the preferred narrower range, is believed to lower the 'L' scale value the darker the flakes. The 'L' scale be more stable with respect to product bulk density. This is to values described herein are also accurate means of defining say, flaked coffee of intermediate thickness ranges is much the degree of roast necessary to produce a coffee which when less susceptible to variable bulk density. flaked gives a product within the “L” scale values herein 0529 Flaked coffee having a flake thickness within the described. Determination of optimum roasting conditions prescribed range has an additional physical characteristic in varies with the coffee employed but is within the skill of one that at least from 70 to 85 percent of the coffee cells are knowledgeable in the field and can be determined after a few disrupted, as revealed by microscopic examination. This Hunter Color measurements of degrees of roast and compari large amount of cellular disruption is advantageous in that 33 Son of the roasted and ground color values with the roasted percent more cups of coffee of uniform beverage strength can ground and flaked color values. be prepared from a given weight of flaked coffee having a 0533. Certain roll milling processing conditions are flake thickness of from 0.008 inch to 0.025 inch than from the believed to be especially desirable in producing flakes having same weight of roast and ground non-compressed, i.e. non the desired physical characteristics such that the tendency for flaked, coffee. While not wishing to be bound by any theory, variation in bulk density is eliminated. Generally speaking, it is believed this is so primarily because flaked coffee within these conditions are roll temperature, roll pressure, and roll the previously specified thickness range lacks a visible cell diameters. structure, i.e. is amorphous in structure which in turn allows 0534. The temperature of operation of the roll mill in for easy releasing of coffee components in extraction. This is forming flaked roast and ground coffee is normally from 32 contrary to roast and ground coffee wherein the coffee par F. to 300°F. However, for utilization in preparing the flaked ticles are cube shaped and cellular disruption occurs only coffee used in the sixth group of embodiments, the tempera along the sides of the cubes. ture of the roll mill during flaking is not critical. Extremely 0530. In providing an acceptable flaked coffee product it is high temperatures should be avoided because degradation of also essential that the flake moisture level be from 2.5 to 7.0 flavor and aroma constituents of the roast and ground coffee percent by weight. It is preferred that the moisture level be particles can result and extremely low temperatures are not from 3.0 to 6.0 percent. Lower moisture contents than 2.5 practical in that the use of refrigeration equipment is neces percent are to be avoided because the resulting flake is very sitated. In the usual method of operation the coffee particles fragile and often breaks during process handling and packing immediately after being ground are passed through a roll mill Too large a percentage of broken flakes in turn changes the to obtain flaked roast and ground coffee. The ground coffee product bulk density which if it falls without the range of from can, if desired, be allowed to cool to room temperature and 0.38 g/cc. to 0.50 g.fcc. will produce a consumer unaccept subsequently passed through the roll mill to form flakes of able product. On the other hand moisture contents above 7.0 roast and ground coffee. percent should be avoided because the flakes become tacky 0535 The pressure exerted on the ground coffee by the and oily in appearance. Moreover, if the coffee moisture rollers in the roll mill ranges from 100 lbs./linear inch of nip content is higher than 7.0 percent prior to roll milling to to 10,000 lbs./linear inch of nip and preferably from 600 produce flakes, water extrusion during milling occurs and the lbs./linear inch of nip to 6000 lbs./linear inch of nip. Staling propensity of the resultant flakes is Substantially Extremely high pressures, i.e., above 10,000 lbs./linear inch increased. of nip are to be avoided because with high pressures too much US 2014/0370181 A1 Dec. 18, 2014 34 coffee oil is expelled coating the surface of the roll. The oil on ground coffee particles. It does not include flaked roast and the rolls acts as a lubricant making the flaking operation ground coffee particles which are hereinafter referred to as difficult. Additionally, extremely high pressures make very flaked coffee or roast and ground coffee flakes, the two terms thin, weak flakes. Very low pressures are to be avoided being used interchangeably. because of the insufficient cellular disruption which is neces 0541 Flaked coffee is known in the art. McKinnis, U.S. sary to obtain proper extraction. Pat. No. 1,903,362, Rosenthal U.S. Pat. No. 2,123,207, and 0536 Flakes can be made with one pass through a two roll Carter U.S. Pat. No. 2.368,113 all disclose preparation of mill having roll diameters within a wide range, for example, flaked coffee by roll milling roast and ground coffee. Of these as Small as 4 inches and as large as 80 inches or even larger, three patents the most relevant is McKinnis who discloses but preferably from 6 inches to 30 inches and operating at production of “very thin' and “substantially uniform thick peripheral speeds of from 1 ft/min. up to 1500 ft./min., but ness' coffee flakes by roll milling roast and ground coffee preferably from 10 ft./min. to 900ft./min. The optimum yield particles. of desirable flakes may be obtained when the rolls operate at 0542. The reason for the present lack of a consumer approximately the same speeds. Differential roll speeds, how acceptable flaked coffee product is believed to be because ever, can be utilized. Roll speed ratios in excess of 1.5:1 are heretofore certain essential coffee flake characteristics dis not desirable. Preferably when differential roll speeds are cussed hereinafter were unknown. employed the roll speed ratio is within the range of from 1:1 (0543. Application Ser. No. 30,246, filed Apr. 20, 1970, as to 1.4:1. a continuation-in-part of now abandoned application Ser. No. 0537. The feed rate of the roast and ground coffee to be 823.954, filed May 12, 1969, Joffe, entitled, “Flaked Coffee flaked, into the roll mill is not critical; either choke feeding or and Products Produced Therefrom relates to roast and starve feeding can be employed. Choke feeding is defined as ground coffee flakes having a flake bulk density of from 0.38 having excess amounts of coffee settling on the roll mills grams/cc to 0.50 grams/cc and preferably from 0.42 grams/cc waiting to pass through the nip. It is the opposite of starve to 0.48 grams/cc, and a flake thickness of from 0.008 inches feeding. to 0.025 inches, preferably from 0.10 inches to 0.016 inches, 0538. In preparing the coffee composition for use in a and a flake moisture content of from 2.5 to 7.0 percent, beverage unit as defined in the Summary of the Invention, the preferably from 3.0 to 6.0 percent. The above identified Joffe coffee in the coffee composition 110/130 and beverage mate application, now U.S. Pat. No. 3,615,667, also relates to mix rial 120 as shown in FIGS. 1A, 1B, and 1C may have various tures of the above described roast and ground coffee flakes cell structures. As previously mentioned, flaked roast and and conventional roast and ground coffee particles to produce ground coffee is contemplated in the present invention. Flak a product of excellent aroma, strength and flavor. ing of roast and ground coffee can be used advantageously to 0544 Producing roast and ground coffee flakes having the control or regulate the flavor and aroma of coffee as well as above specified physical characteristics is believed to be the extractability. The seventh group of embodiments accord essential in regard to production of a consumer acceptable ing to the present invention provides a method of making flaked coffee product. flakes of roast and ground coffee wherein said flakes have a 0545 Providing a flaked bulk density within the range of flake bulk density of from 0.38 grams/cc to 0.50 grams/cc, a from 0.38 grams/cc to 0.50 grams/cc is important because flake thickness of from 0.008 inches to 0.025 inches and a bulk densities within this range are generally the bulk densi flake moisture content of from 2.5 to 7.0 percent. The method ties of conventionally prepared roast and ground coffees of comprises passing roast and ground coffee having a moisture “regular,” “drip’ and “fine ground. If the bulk density varies content of from 2.5 to 7.0 percent through a roll mill having a from this range and is, for example, higher, the consumer roll diameter of from 6.0 inches to 30.0 inches, at a roll would need to use Substantially lesser than usual quantities of pressure of from 1,500 lbs./inch of nip to 5,000 lbs./inch of coffee to produce a brew of given strength; this required nip, at a roll surface temperature of from 50°F. to 200°F. and adjustment in consumer habits might be made with some at a roll peripheral surface speed of from 100 ft./min. to 1,500 difficulty. ft/min. 0546 Providing roast and ground coffee flakes having a 0539. The seventh group of embodiments relates to a flake thickness of from 0.008 inches to 0.025 inches is impor method of making flakes of roast and ground coffee wherein tant in producing roast and ground coffee flakes having the said flakes have a flake bulk density of from 0.38 grams/cc to requisite bulk density as previously discussed and in produc 0.50 grams/cc, a flake thickness of from 0.008 inches to 0.025 ing flakes which do not have a propensity towards changing in inches and a flake moisture content of from 2.5 to 7.0 percent, bulk density after packing said method comprising passing roast and ground coffee hav 0547 Providing roast and ground coffee flakes having a ing a moisture content of from 2.5 to 7.0 percent through a roll flake moisture level of from 2.5 to 7.0 percent by weight is mill having a roll diameter of from 6.0 inches to 30.0 inches, important because flakes having lower moisture contents are at a roll pressure of from 1,500 lbs./inch of nip to 5,000 too fragile and often break during processing and packaging. lbs./inch of nip, at a roll surface temperature of from 50°F. to Such breaking changes the product bulk density, which if it 200 F. and at a roll peripheral surface speed of from 100 falls without the range of from 0.38 grams/cc to 0.50 grams/ ft/min. to 1,500 ft./min. This process produces consumer cc, will produce a consumer unacceptable product. On the acceptable coffee flakes at consistently high yields and fur other hand, moisture contents above 7.0 percent are consumer ther produces flakes of high structural integrity and flakes unacceptable because the flakes become tacky and oily in having little or no flavor degradation. appearance. 0540. In connection to the background of the first group of 0548. In summary, the Joffe application, which is incor embodiments, the term roast and ground coffee refers to a porated herein by reference, discloses and claims a flaked coffee product comprising conventionally prepared roast and coffee having a carefully controlled bulk density, flake thick ground coffee particles and also decaffeinated roast and ness and moisture content, all of which have been found US 2014/0370181 A1 Dec. 18, 2014 important in producing consumer acceptable coffee flakes. found important to control at least five processing variables. Hereinafter, the coffee flakes having the above described These variables are roll pressure, roll surface temperature, physical characteristics disclosed and claimed in the Joffe roll peripheral Surface speed, roast and ground coffee mois application will be referred to as consumer acceptable coffee ture content and roll diameters. An additional variable which flakes. is not as important, but because it helps in producing higher 0549. In regard to specific processing conditions, the prior yields and therefore should preferably be carefully con art patents are vague and merely teach passing roast and trolled, is roast and ground coffee particle size. ground coffee through a roll mill. It is believed that the coac 0555 Roll pressure is measured in pounds per inch of nip. tion of particular roll milling processing variables within the Nip is a term used in the art to define the length of surface hereinafter described ranges provides high yields of flaked contact between two rolls when the rolls are at rest. To illus coffee having the requisite physical characteristics for con trate, it can be thought of as a line extending the full length of Sumer acceptable flakes. While Some processing conditions the rolls and defining the point of contact between two rolls. not within the hereinafter described ranges produces some 0556. To produce high yields of the heretofore described flakes having the requisite bulk density, thickness and mois consumer acceptable flaked coffee, it is important that the roll ture content, operation within the specified ranges insures pressure be within the range of from 1,500 lbs./inch of nip to consistently high yields of flakes of high structural integrity 5,000 lbs./inch of nip and preferably within the range of from which have little or no flavor degradation. Broadly, this appli 2,000 lbs./inch of nip to 4,000 lbs./inch of nip. If pressures cation relates to a specific method of producing roast and much less than 1,500 lbs./inch of nip are employed, the result ground coffee flakes having the above-enumerated essential ing product may not have a flaked coffee appearance. More physical characteristics. over, any flakes that are produced are much thicker than 0.025 0550 Accordingly, it is an object of the seventh group of inches and consequently the flakes are not consumer accept embodiments to provide a method of making the roast and able. On the other hand, if pressures in excess of 5,000 lbs./ ground coffee flakes claimed in Joffe, entitled “Flaked Coffee inch of nip are employed the roast and ground coffee flakes and Products Produced Therefrom by a procedure which tend to be thinner than 0.008 inches and the product bulk insures consistently high yields of flakes of high structural density is less than the required minimum of 0.38 grams/cc integrity having little or no flavor degradation. needed for a consumer acceptable coffee flake. Additionally, 0551 One aspect of the seventh group of embodiments at pressures in excess of 5,000 lbs./inch of nip the roll friction provides for a coffee composition for use in a beverage unit produces excessive amounts of heat which as hereinafter and method thereofas defined in the Summary of the Inven related also tends to produce thin, undesirable flakes having tion, wherein the coffee composition comprises flakes of unacceptable bulk densities. For overall process efficiency roast and ground coffee wherein said flakes have a flake bulk roll pressures within the range of from 2,000 lbs./inch of nip density of from 0.38 grams/cc to 0.50 grams/cc, a flake thick to 4,000 lbs./inch of nip are preferred. ness of from 0.008 inch to 0.025 inch, and a flake moisture 0557. Roll surface temperature, as used herein, is mea content of from 3.0 to 6.0 percent, made from a method Sured in degrees Fahrenheit and refers to the average Surface comprising passing roasted and ground coffee having a mois temperature of the rolls. Control of roll mill surface tempera ture content of from 3.0 to 6 percent through a roll mill having tures is accomplished by controlling the temperature of a heat a roll diameter of from 9 inches to 25 inches, at a roll pressure exchange fluid passing through the inner core of the rolls. offrom 2,000 lbs./inch of nip to 4,000 lbs./inch of nip, at a roll Generally, the fluid, which is most often water, is heated or surface temperature of from 110° F. to 180° F. and at a roll cooled and passed through the inside of the rolls. The result is peripheral surface speed of from 350 ft/min. to 800 ft/min. that the roll surface which is usually a smooth, high polished removing from said roll mill on a weight basis of the feed steel Surface, is subjected to temperature control by means of roast and ground coffee a yield of flaked coffee of over 80 heat transfer. Of course, in actual operation the Surface tem percent to provide a flaked coffee product of high structural perature will likely not be exactly the same as the temperature integrity, which does not have a propensity towards changing of the heat exchange fluid and will be somewhat higher bulk density after packing. because milling of coffee particles to produce flakes tends to 0552. In more specific examples, the roast and ground increase the roll Surface temperature. Accordingly, the coffee to be flaked is decaffeinated coffee. The roast and required heat exchange fluid temperature to maintain any ground coffee (e.g. regular grind) to be flaked is further char specific roll Surface temperature can depend upon several acterized by having a particle size of from 0.0 to 18.0 percent factors such as the kind of metal the roll surfaces are made of on 12 mesh, from 0.0 to 46.0 percent on 16 mesh, from 15.0 the speed of operation of the roll mills, and the heat exchange to 50.0 percent on 20 mesh, from 7.0 to 30.0 percent on 30 fluid employed. mesh, from 4.0 to 15.0 percent on 40 mesh and from 3.0 to 8.0 0558 Generally, it can be stated that higher roll surface percent through a 40 mesh. temperatures will tend to produce thinner flakes of roast and 0553. The seventh group of embodiments as described ground coffee. Additionally, at higher temperatures the pro above will be further described in the following paragraphs pensity for flavor degradation becomes increased. On the and exemplified in Example 26. other hand, lower roll surface temperatures will tend to pro 0554) Informing flaked roast and ground coffee, roast and duce thicker flakes with little or no flavor degradation. To ground coffee is Subjected to a mechanical pressure by pass produce the consumer acceptable flaked roast and ground ing roast and ground coffee through two parallel Smooth or coffee heretofore described it is important that the roll surface highly polished rolls so that the coffee particles passing temperature be within the range of from 50° F. to 200° F. between the rolls are crushed and flattened such that the Temperatures less than 50 F. are undesirable because expen coffee cellular structure is disrupted and the resulting appear sive cooling systems must be employed and at Such low ance is that of a flake. In roll milling roast and ground coffee temperatures the flake thickness tends to be greater than 0.025 to produce consumer acceptable flaked coffee, it has been inches; consequently, the flakes are consumer unacceptable. US 2014/0370181 A1 Dec. 18, 2014 36
Additionally, at temperatures less than 50 F. the resultant is required to soften the coffee cellular construction thereby coffee flakes are very brittle and have a tendency to break making it more susceptible to flaking during milling. On the during Subsequent processing and packaging. This is unde other hand, moisture contents above 7.0 percent are to be sirable because breaking of brittle flakes results in a change in avoided because the flakes become unsightly in appearance. product bulk density which may affect the consumer accept Moreover, if the coffee moisture content is higher than 7.0 ability of the coffee flakes produced. Such weak flakes often percent, prior to milling to produce flakes, the Staling propen have bulk densities not within the range of consumer accept sity of the resultant flakes is substantially increased. Provid able flake bulk densities. ing a moisture content of the roast and ground coffee to be 0559 To produce flaked roast and ground coffee having flaked within the range of from 3.0 to 6.0 percent provides the the hereinbefore defined consumer acceptable bulk density, highest yield of consumer acceptable flaked coffee coupled flake thickness and moisture content, it is preferred that the with little or no flavor degradation and is therefore preferred. roll mill surface temperature be within the range of from 110° 0563. In regard to the particle size of the roast and ground F. to 180° F. When roll surface temperatures within this range coffee employed in the flaking process no criticality exists. are employed the majority of the resultant coffee flakes are of However, from the standpoint of producing consumer appeal a proper thickness to produce a consumer acceptable bulk ing flaked coffee appearance, it is preferred that the roast and density coupled with a product having high structural integ ground coffee particles have a particle size of from 0.0 to 18.0 rity and little or no flavor degradation. percent retained on a 12 mesh U.S. Standard screen, from 0.0 0560. The roll peripheral surface speed is measured in feet to 46.0 percent retained on a 16 mesh U.S. Standard Screen, per minute of surface circumference which passes by the nip. from 15.0 to 50.0 percent retained on a 20 mesh U.S. Standard Generally, higher peripheral Surface speeds produce thinner Screen, from 7.0 to 30.0 percent retained on a 30 mesh U.S. flakes and conversely lower peripheral Surface speeds pro Standard Screen, from 4.0 to 15.0 percent retained on a 40 duce thicker flakes. Here again, the interplay of the milling mesh U.S. Standard Screen and from 3.0 to 8.0 percent pass conditions can be seen. For instance, at higher peripheral ing through a 40 mesh U.S. Standard Screen. Speaking in Surface speeds friction increases the roll Surface temperature more familiar terms, the roast and ground coffee to be flaked which tends to produce thinner consumer unacceptable cof can be “regular,” “drip’ or “fine grind as these terms are used fee flakes. Thus, roll peripheral surface speeds which result in in a traditional sense. The standards of these grinds as Sug roll surface temperatures above 200 F. should not be gested in the 1948 Simplified Practice Recommendation by employed. On the other hand, extremely low roll peripheral the U.S. Department of Commerce (see Coffee Brewing surface speeds tend to produce thicker and less consumer Workshop Manual, page33, published by the Coffee Brewing acceptable flakes. Roll peripheral speeds within the range of Center of the Pan American Bureau are as follows: “Regular 100 ft./min. to 1,500 ft./min. are important in producing grind, 33 percent is retained on a 14 mesh Tyler Standard flaked roast and ground coffee having the hereinbefore Sieve, 55 percent is retained on a 28 mesh Tyler Standard defined consumer acceptable flake characteristics. If roll Sieve and 12 percent passes through a 28 mesh Tyler Standard peripheral surface speeds in excess of 1,500 ft./min. are Sieve; "drip grind.” 7 percent is retained on a 14 mesh Tyler employed, the resultant flakes are too thin for consumer Standard Screen, 73 percent on a 28 mesh Tyler Standard acceptability. Moreover, at speeds in excess of 1,500 ft./min. Sieve and 27 percent passes through a 28 mesh Tyler Standard the heat of friction is so great that the roll surface tempera Sieve; and “fine grind' 100 percent passes through a 14 mesh tures cannot be maintained at or less than the maximum Tyler Standard Sieve, 70 percent being retained on a 28 mesh temperature of 200°F. Consequently, a significant amount of Tyler Standard Sieve and 30 percent passing through a 28 flavor degradation of the flaked coffee occurs. On the other mesh Tyler Standard Sieve. Of the above mentioned tradi hand, at roll peripheral surface speeds less than 100 ft/min. tional grind sizes the most preferred is “regular grind.” the rate of production of flaked roast and ground coffee is so slow as to be commercially impractical. Especially preferred 0564. As can be seen from the foregoing description, the roll peripheral surface speeds which allow for easy tempera grind size of the roast and ground coffee to be flaked does not ture control and desirable throughput rates are from 350 ft./ represent a critical aspect of the flaking method of the seventh min. to 800 ft/min. group of embodiments; however, while the particle size is not 0561. In further regard to the roll peripheral surface critical, it is desirable to regulate the particle size because this speeds, it should be mentioned that optimum yields of con in turn regulates the sieve analysis of the resulting roast and Sumer acceptable flakes are generally obtained when the rolls ground coffee flakes. This can be important in producing a operate at approximately the same speeds. Differential roll flaked coffee product having different “grind sizes, i.e., speeds, however, can be utilized. Roll speed ratios in excess “regular grind,” “fine grind,” and "drip grind' as those terms of 1.5 to 1.0 are not desirable. Preferably when differential are used in their traditional sense. roll speeds are employed the roll speed rate is within the range 0565. The diameter of the roll mills employed controls the of greater than 1:1 up to 1.4:1. However, in no event should angle of entry into the nip. The angle of entry into the nip in the speed of the fastest roll be in excess of 1,500 ft./min. turn has a direct effect on the flake thickness, and conse 0562. In producing consumer acceptable flaked roast and quently on the bulk density of the resultant roast and ground ground coffee it is important that the flake moisture content be coffee flakes. To produce the hereinbefore defined consumer from 2.5 to 7.0 percent by weight, with from 3.0 to 6.0 percent acceptable flaked roast and ground coffee it is important that being preferred. Consequently, the moisture content of the the roll diameter be within the range of from 6 inches to 30 roast and ground coffee particles to be flaked should be within inches with from 9 inches to 25 inches being preferred. If rolls the range of from 2.5 to 7.0 percent. At moisture contents less having a diameter of less than 6 inches are utilized the roast than 2.5 percent the roast and ground coffee is too dry to flake and ground coffee particles tend to churn on the mill Surfaces during roll milling and has a tendency to grind rather than and not pass through the nip; consequently, the throughput flake. A minimum moisture content of 2.5 percent by weight rate of the roast and ground coffee to be flaked becomes so US 2014/0370181 A1 Dec. 18, 2014 37 slow as to be impractical. Roll mills having roll diameters 0571. Two more important advantages of this process are greater than 30 inches may not be readily commercially avail that the flakes produced by this process are of high structural able. integrity and have undergone little or no flavor degradation. 0566. As can be seen from the foregoing description the Producing flakes of high structural integrity (i.e. physically ranges of each of the described milling process variables are strong and not easily Susceptible to breakage during packing) closely tied to and correlated with each of the other process is important because large percentages of broken flakes may ing variables. A change in one variable often has a direct change the product bulk density and is known to present a effect in changing another variable. For instance, operation at consumer unappealing appearance. The fact that little or no high roll pressures, in excess of 5,000 lbs./inch of nip, coffee flavor degradation occurs during operation of the pro increases the frictional resistance which in turn generatesheat cess of the seventh group of embodiments is, of course, and increases the roll Surface temperature. The increased important in respect to consumer preference for the product. inward pressure at the nip of the roll mills coupled with the 0572. In preparing the coffee composition for use in a resulting higher temperatures produces thin, weak flakes; and beverage unit as defined in the Summary of the Invention, the if the pressure is sufficient to increase the roll surface tem coffee in the coffee composition 110/130 and beverage mate perature above 200°F. the flaked coffee undergoes a flavor rial 120 as shown in FIGS. 1A, 1B, and 1C may have various degradation. Likewise, roll peripheral Surface speeds in cell structures. As previously mentioned, flaked roast and excess of 1,500 ft./min. may produce some flakes of proper ground coffee is contemplated in the present invention. Flak thickness for consumer acceptability but because of the ing of roast and ground coffee can be used advantageously to increase of roll Surface temperatures which accompanies the control or regulate the flavor and aroma of coffee as well as high speed, the flakes will be of inferior structural integrity the extractability. The eighth group of embodiments accord and often will have undergone flavor degradation; moreover, ing to the present invention provides extra-thin flaked roast the yield of flakes of proper thickness and density will be and ground coffee with structural integrity and increased substantially decreased. Thus, the flaking procedure of the extractability for a less acidic beverage and a novel process seventh group of embodiments takes into account the inter for making same. related and coacting nature or roll pressure, roll temperatures, 0573. In the eighth group of embodiments, it is believed coffee moisture levels, roll diameter, roll peripheral surface that a superior coffee product is provided by a thin-flaked speed and to a lesser extent the particle size of the roast and roastand ground coffee product having a minimum amount of ground coffee to be flaked. The result of operation of each of coffee flakes which have a flake thickness within a very select these process variables within the hereinbefore described flake thickness range. ranges is that high yields of consumer acceptable flaked roast 0574. The eighth group of embodiments provides a and ground coffee having little or no flavor loss and further method for preparing that thin-flaked roast and ground coffee characterized by having Suitable structural integrity to pre which exhibits enhanced extractability and yet possesses con vent breaking when packaging, is produced. Sumer-acceptable flake physical properties. It is believed that 0567. The feed rate into the roll mill, of the roast and the thin-flaked roast and ground coffee of superior extract ground coffee to be flaked, is not critical; either choke feeding ability and structural integrity is provided by the novel flaking or starve feeding can be employed as long as the previously method described herein, comprising flaking roast and discussed processing variables are operated within their pre ground coffee having a particle size within a very select size scribed ranges. Choke feeding is defined as having excess range and moisture level by roll milling the unflaked R&G amounts of coffee settling on the roll mills waiting to pass coffee under particular roll mill operating conditions. through the nip. It is the opposite of starve feeding. 0575. In connection to the background of the eighth group 0568. In further regard to the feeding rate, where either of embodiments, numerous attempts have been made in the starve feeding or choke feeding can be employed, starve past to increase the extractability of roast coffee of those feeding is preferred because of particular process advantages flavorful water-soluble constituents often referred to as brew offered by starve feeding Such as greater economic efficiency, Solids. That is, attempts have been made to increase the increased equipment life and increased process flexibility. amount of brew solids which are able to be extracted from a For a detailed description of starve feeding see Menzies et al., given weight of coffee from which a coffee brew is made. entitled “A Method of Starve Feeding Coffee Particles.” Ser. 0576. It is known that the extractability of roast coffee may No. 823.900, now abandoned, and Menzies, “An Apparatus be increased by grinding the coffee to finer particle sizes. For Starve Feeding Coffee Particles.” Ser. No. 823,901, now However, roast coffee products ground to very fine grinds abandoned. have bed-permeability characteristics which inhibit the 0569. In regard to the types of roast and ground coffee extraction of the water-soluble constituents due to bed com utilized in the flaking process of the seventh group of embodi paction, pooling, channeling, etc. To avoid Such brewing ments see the previously incorporated by reference applica problems, it has been conventional to provide roast coffee tion of Joffe entitled, “A Flaked Coffee Product.” ground to mixtures of variously sized particles, such as the 0570. As indicated previously, the process of the seventh traditional grinds of “regular”, “drip’ and “fine”. group of embodiments not only produces consumer accept 0577. Other than adjusting the particle size distribution by able flakes but also produces them at consistently high yields, grinding, relatively little effort has been directed toward alter i.e., yields on a weight basis of over 80 percent and usually in ing the fundamental physical characteristics of coffee. Green excess of 90 percent. Such high yields are highly desirable in coffee beans have been roll-milled prior to roasting and grind producing a consumer product on a large scale. Yield as used ing to increase the extractability of coffee (see U.S. Pat. No. herein refers to the percent on a weight basis of flakes having 2,123,207, issued Jul. 12, 1938 to Rosenthal). Roast and the requisite physical characteristics for consumer accept ground coffee has been light-milled to provide a coffee prod ability, particles not meeting these criteria are screened out uct which has the same bulk appearance as conventional roast and can be recycled for further processing. and ground coffee but which has increased extractability (see US 2014/0370181 A1 Dec. 18, 2014
U.S. Pat. No. 3,769,031, issued Oct. 26, 1973 to J. R. methods have been unable to produce thin-flaked roast and McSwinggin). Flaked green coffee has also been subjected to ground coffee exhibiting desirable physical properties. compressive and shear forces via extruder roasting to provide 0583. One aspect of the eighth group of embodiments a roast coffee product which yields higher soluble solids (see, provides for a coffee composition for use in a beverage unit for example, U.S. Pat. No. 3,762.930, issued Oct. 2, 1973 to and method thereofas defined in the Summary of the Inven J. P. Mahlmann). Although these efforts may result in some tion, wherein the coffee composition comprises a thin flaked level of improvement in extracting desirable coffee flavor coffee product having improved structural integrity and constituents, further enhancement of coffee's extractability is enhanced extractability for a less acidic beverage, made from provided by flaked roast and ground coffee. a method of flaking roast and ground coffee comprising the 0578 Roast and ground coffee has been transformed into steps of: flaked coffee by roll milling the roast and ground coffee (see, 0584 (1) passing through a roll mill coarse roast and for example, U.S. Pat. No. 1,903,362, issued Apr. 4, 1933 to ground coffee having a coarse particle size distribution Such R. B. McKinnis and U.S. Pat. No. 2,368,113, issued Jan. 30, that: 1945 C. W. Carter). Thick-flaked (i.e., flaked coffee having an 0585 (a) from about 90% to 100% by weight is retained average flake thickness greater than 0.008 inch) roast and on a No. 30 U.S. Standard Screen, ground of enhanced extractability is disclosed by Joffe in U.S. 0586 (b) from about 51% to 89% by weight is retained Pat. No. 3,615,667, issued Oct. 26, 1971 as well as a method on a No. 16 U.S. Standard Screen, and for its production in U.S. Pat. No. 3,660,106, issued May 2, 0587 (c) from about 20% to 50% by weight is retained 1972 to J. R. McSwiggin et al. A visually appealing high on a No. 12 U.S. Standard Screen, sheen flaked roast and ground coffee of improved extractabil 0588 (2) operating said roll mill: ity is disclosed in U.S. Pat. No. 4,110,485, issued Aug. 29. 0589 (a) at a static gap setting of less than about 0.1 1978 to Grubbs. 0579. In contrast to the consumer acceptability of thick 0590 (b) a roll peripheral speed of from about 150 flaked roast and ground coffee, both the Joffe 667 patent and meters/min. to about 800 meters/min., the McSwiggin 106 patent teach that thin-flaked coffee hav 0591 (c) a roll temperature of below about 40°C., and ing an average flake thickness of less than 0.008 inch is taught 0592 (d) at a pressure of about 100 kilomewtons/meter to be consumer-unacceptable. The thin-flaked coffee pro to about 400 kilomewtons/meter of nip, and duced by Such prior art methods is described as having a 0593 wherein the rolls of said roll mill have a roll diam "cellophane-like nature and, therefore, visually unappeal eter of at least about 15 cm, and ing. Moreover, the “cellophane-like thin flakes are also dis 0594 wherein the resultant thin flaked coffee comprises: closed as being undesirably fragile and have both an unac 0595 thin flakes of roast and ground coffee, wherein about ceptably low and a variable bulk density (Joffe 667, Column 80% to about 98% by weight of said flakes have an average 8, lines 46-54). thickness of from about 0.1 mm. to about 0.175 mm., 0580. The prior art teaches that the fragile nature of the 0596 said improved roast and ground coffee product hav thin flakes of the prior art leads to product breakup during ing a particle size distribution such that about 30% to about normal packaging, transportation and handling. The product 90% by weight of said product passes through a No. 30 U.S. breakup is accompanied by the flakes aligning themselves in Standard sieve, parallel planes producing a very compact product with a bulk 0597 said product having a tamped bulk density of from density Substantially higher than that of roast and ground about 0.35 g/cc. to about 0.50 g.fcc., and coffees presently marketed. When the parallel plane align 0598 a moisture content of from about 2.5% to about ment takes place after packaging, there occurs an objection 9.0% by weight. able increase in container outage (i.e. the space between the 0599. In more specific examples under this aspect, said upper Surface of the product and the upper Surface of the operating roll force is from about 200 kilomewtons to about container). Large container outages are viewed negatively by 400 kilomewtons per meter of nip. Said coarse roast and the consumer. Thus, the thin-flaked roast and ground coffee ground coffee has a moisture content of from about 3.5% to produced by art-known methods is consumer unacceptable. about 7% by weight. Said thin flaked coffee product has a moisture content of from about 3.5% to about 5%, and 0581. Given the state of the coffee art as described above, wherein about 40% to about 70% of said product passes there is a continuing need to provide a roast and ground coffee through a No. 30 U.S. Standard sieve. Said operating roll product which provides improved extractability of soluble temperature is from about 5° C. to about 30° C. Said thin brew solids and which possesses consumer acceptable physi flakes have at least 50% of their microscopic observable cal properties and appearance. Accordingly, it is an object of internal and surface cells disrupted. Said tamped bulk density the eighth group of embodiments to provide a roast and is from about 0.38 to about 0.48. ground coffee product exhibiting desirable organoleptic and 0600. In more specific examples under this aspect, said physical properties. thin flakes have an average thickness of less than about 0.175 0582 The methods known in the art for preparing flaked mm. They may have at least about 50% of said internal and roast and ground coffee comprise passing roast and ground surface cells disrupted. They may have about 70% to about coffee through a roll mill under particular conditions of roll 85% of said internal and surface cells disrupted. pressure, roll peripheral speed, roll temperature, roll diam 0601. In more specific examples under this aspect, said eters, and flake moisture content. While known methods of thin flakes have about 70% to about 85% of their microscopic making flaked coffee having realized thick-flaked roast and observable internal and surface cells disrupted and yet said ground coffee which provides an extractability advantage flakes have Substantial structural integrity to provide a Sub compared to conventional roast and ground coffee and pos stantially non-fragile non-cellophanelike improved thin sesses consumer acceptable flake physical properties, these flaked coffee product. For example, the moisture content of US 2014/0370181 A1 Dec. 18, 2014 39 the flakes is from about 3.5% to about 7%, and about 40% to ments are disrupted. That is, the cellular disruption specu about 70% of said product passes through a No. 30 U.S. lated to be responsible for increased extractability is not Standard sieve. For another example, said thin flakes may confined to the surface regions of the flake. The cellular have a substantial portion of their microscopic observable disruption of the interior of the thin-flaked coffee herein is internal and Surface (cells disrupted and yet have substantial believed caused by the particular combination of conditions structural integrity to provide a Substantial non-fragile herein disclosed, including a more severe compressive force improved thin flaked coffee product. required to transform the relatively large “coarse' grind size 0602. The eighth group of embodiments as described roast and ground coffee feed into the thinner thin-flaked cof above will be further described in the following paragraphs fee of the eighth group of embodiments, as explained in more and exemplified in Examples 27-29. detail below. 0603 The eighth group of embodiments relates to thin 0607. The greater extractability provided by the novel flaked roast and ground coffee products of improved extract thin-flaked coffee provided herein enables more cups of ability of the water-soluble flavor constituents. There is fur equal-brew strength and flavor to be brewed from a given ther provided herein an improvement in the coffee flaking amount of coffee. The normal method of measuring the process enabling the provision of the thin-flaked coffee prod strength of a coffee brew is to measure the percent soluble uct herein. solids which is more commonly referred to as brew solids. This measurement can be made by oven-drying the brewed Thin-Flake Coffee coffee and weighing the remainder. The percent soluble sol ids can also be ascertained optically by measuring the index 0604. In the provision of a thin-flaked roast and ground of refraction of the coffee brew. The index of refraction is coffee product of enhanced extractability and low acidity, it is correlated to brew solids as measured by the oven-drying important to control the flake thickness, particle size distri technique. Although the extractability of acidity constituents bution, bulk density and flake moisture content in order to is also increased, it is believed that the increase is proportion insure its consumer acceptability. Each of these coffee prod ately smaller than the increase in flavor constituents. There uct properties, as well as product preparation and product use, fore, not only could more cups of equal-brew strength be are described in detail as follows: brewed from a given amount of thin-flaked coffee, but the equal-brew strength cups would also have lower titratable A. Flake Thickness acidity. 0605. The improved coffee flaking process described 0608. The thin-flaked coffee provided herein can be made hereinafter can provide flakes of almost any desired thick from a variety of roast and ground coffee blends including ness. However, it is believed that a flaked coffee product of those which may be classified for convenience and simplifi superior increased extractability of the desirable coffee flavor cation as low-grade, intermediate grade and high-grade cof constituents can be realized if the thickness of the coffee fees. Examples and blends thereof are known in the art and flakes are within a very select flake thickness range. The terms illustrated in, for example, U.S. Pat. No. 3,615,667 (issued “coffee flakes' or “flaked coffee', as used interchangeably Oct. 26, 1971 to Joffe) herein incorporated by reference in its herein, refer to compressed roast and ground coffee. The term entirety. “flake thickness” as used herein means the average thickness 0609 Decaffeinated roast and ground coffee can also be of the flakes passing through a No. 12 U.S. Standard Sieve used to make a decaffeinated thin-flaked coffee product. As is and remaining on a No. 16. The improved thin-flaked coffee known in the art, the removal of caffeine from coffee products product provided herein comprises flaked roast and ground frequently is accomplished at the expense of the removal of coffee wherein about 80% to about 98% by weight of the certain other desirable components which contribute to fla flakes have a flake thickness ranging from about 0.1 mm to vor. The tendency of decaffeinated products to be either weak about 0.2 mm (i.e. about 0.004 inch to 0.008 inch), preferably or deficient in flavor has, thus, been reported in the literature. about 0.125 to about 0.175 mm. Such thin flakes provide The provision of thin-flaked coffee made from decaffeinated improved extractability of the water-soluble coffee constitu roast and ground coffee by the novel thin-flaking method of ents compared to the thicker flaked coffee products disclosed the eighth group of embodiments provides a compensatory by the prior art or commercially sold. advantage. The added flavor and strength advantages achiev able by enhanced extractability permits realization of levels 0606 While not wishing to be bound by the proposed of flavor and brew strength which might otherwise not be theory, it is believed that the increased extractability com attainable in the case of a conventional decaffeinated roast pared to prior art flaked coffee, particularly flaked coffee and ground product. having a flake thickness exceeding 0.2 mm, is due to the increased internal cellular disruption of the thin coffee flakes 0610 Typically, decaffeination of coffee is accomplished made by the process of the eighth group of embodiments. by solvent extraction prior to the roasting of green coffee Although the prior art teaches that thicker coffee flakes have beans. Such decaffeination methods are well known in theart. 70% to 85% of the coffee cells disrupted, as revealed by After roasting, the decaffeinated beans are ground to the microscopic evaluation, Such cellular disruption is evident suitable particle size, described in more detail below, and are only in the planar Surface regions of the prior art flakes. thereafter roll-milled according to the method of the eighth Microscopic evaluation of a “cross-section' of such thicker group of embodiments which is also described in more detail coffee flakes reveals that the cellular disruption indicated is below. confined to the regions near the Surface of the flake plane. A cross-section of the thin-flaked coffee of the eighth group of B. Particle Size Distribution embodiments, however, reveals that substantially all, i.e. 0611. As noted above, the thin-flaked coffee provided from 50% to almost 100%, of the cells exposed from a cross herein has a flake thickness within a select, very particular section view of the thin flakes of the eighth group of embodi thickness range. It is also important to control the dimension US 2014/0370181 A1 Dec. 18, 2014 40 which characterizes the particle size of the coffee flakes. It is ally desirable to aroma-enrich the thin-flaked coffee product conventional in the coffee art to describe coffee particle size of the eighth group of embodiments so as to restore or distribution, including flaked coffee, in terms of sieve frac enhance the aroma to approximate that of fresh roast and tions, i.e. that weight percentage which remains on a particu ground coffee. lar sieve or that weight percentage which passes through a 0617. A variety of methods are known in the art for pro particular sieve. viding coffee products with coffee aromas, for example, U.S. 0612. It is believed that coffee products comprising 60% Pat. No. 2,947,634, Aug. 2, 1960 to Feldman et al., U.S. Pat. or more of fine particles experience decreased extractability No. 3,148,070, Sep. 8, 1964 to Mishkin et al., and U.S. Pat. which drops dramatically as the average particle size No. 3,769,032, Oct. 30, 1973 to Lubsen et al., each of which decreases. The thin-flaked coffee products of the eighth group is herein incorporated by reference in its entirety. These pat of embodiments should have no more than 90% by weight ents describe methods for aromatizing soluble powders by passing through a No. 30 U.S. Standard screen, and prefer addition of an edible carrier oil, such as coffee oil, triglyceride ably from about 40% to about 70% passing through a No. 30 Vegetable oil, propylene glycol and carrying Volatile coffee U.S. Standard screen. This particle size distribution insures aromas. Aroma-enriched carrier oil is generally prepared by efficient extraction. mixing the carrier oil with an aromafrost, allowing the mix ture to equilibrate and allowing the mixture to liquify. An C. Bulk Density aromafrost can be obtained by the condensation of the aroma 0613. The thin-flaked coffee product of the present devel constituents from a variety of sources. Suitable examples of opment should have a bulk density of from 0.35 g/cc. to 0.50 aromatizing coffee volatiles are those obtained from roaster g/cc and preferably 0.38 to 0.48 g/cc in order to assure and grinder gases and from the condensation of steam-dis proper performance. Fortunately, the eighth group of embodi tilled volatile aromas. Examples of suitable aroma materials ments provides flakes of high structural integrity. The desir are described in said U.S. Pat. No. 2,947,634 to Feldman et ability of flakes of high structural integrity (i.e. physical al., U.S. Pat. No. 3,148,070 to Mishkin et al., U.S. Pat. No. strength and resistance to attrition or breakage during han 2,562.206 to Nutting, U.S. Pat. No. 3,132,947 to Mahlmann, dling) is important because large percentages of broken flakes U.S. Pat. No. 3,615,665 to White et al., and Strobel U.S. Pat. markedly change the product bulk density and particle size No. 3,997,683. distribution, which in turn adversely affect the brewing prop erties of the product. Preparation of Thin-Flaked Coffee 0618. The thin-flaked roast and groundcoffee of the eighth D. Flake Moisture Content group of embodiments can be formed by Subjecting conven 0614 The thin-flake coffee composition disclosed herein tional roast and ground coffee to the compressive pressures of has, on the average, a flake moisture level of from about 2.5% a roll mill. The roast and ground coffee is first passed through to about 9.0% by weight, preferably from about 3.5% to about the roll mill, which comprises a pair of parallel, smooth or 7.0%, and most preferably 3.5% to about 5.0%. Of course, it highly polished rolls that crush and flatten the coffee into is recognized that individual flakes can have different indi flakes. Thereafter, the flaked coffee so produced is sized by vidual moisture contents. However, the weight percentages of Suitable means to achieve the requisite particle size distribu such flakes should be controlled such that the coffee product tion. as a whole has average moisture content within the above given range. Moisture contents lower than 2.5% are to be A. Roll Milling avoided because the resulting flakes are very fragile and often 0619. In the step of roll milling roast and ground coffee to break during process handling and packing Too large a per produce consumer-acceptable flaked coffee, it is important to centage of broken flakes in turn changes the product bulk control at least several processing variables: particle size density which if it falls without the range of from 0.35 g/cc. distribution, roll pressure, roll Surface temperature, static gap, to 0.50 g.fcc. and, as noted above, will produce a consumer roast and ground feed moisture content, feed rate, roll periph unacceptable product. On the other hand, moisture contents eral Surface speed, and roll diameters. These and other pro above 7.0% are less desirable. cessing variables are described in detail hereinafter. 0615 Typically, flake moisture content is adjusted by varying the moisture level of the roast and ground coffee feed 1. Particle Size Distribution from which the flakes are produced. The adjustments to the 0620. In marked contrast to the teachings of the art, the feed moisture level can be controlled, for example, by con particle size distribution of the roast and ground coffee feed is trolling the amount of water used to quench and to thereby believed to be an important process variable in the production halt the exothermic roasting operation. The moisture content of thin-flaked coffee of higher extractability. Prior art pro of the roasted beans is not appreciably affected by grinding or cesses have utilized grind sizes traditionally referred to as even by the flaking operations unless high roll Surface tem “regular”, “drip’ and “fine.” The standards of these grinds, as peratures are used. suggested in the 1948 “Coffee Grinds: Simplified Practice Recommendation R231-48”, published by the Coffee Brew E. Aroma-Enriched, Thin-Flaked Coffee ing Institute, Inc., New York, herein incorporated by refer 0616 Penalty exacted by the flaking operation is the loss ence in its entirety. of aroma constituents usually associated with fresh roast and 0621. It is believed, however, that larger “coarse' grind ground coffee. This relative deficiency in the aromas charac size particles are suitable in the novel method of making the teristic of fresh roast and ground coffee has been attributed to thin-flaked coffee disclosed herein. The term “coarse' grind the loss of aroma principles during the roll milling of roast is used liberally in the coffee art to characterize grinds of and ground coffee into flakes. Accordingly, it may be option widely varying particle size distributions. As used herein, US 2014/0370181 A1 Dec. 18, 2014
'coarse' grind size indicates that the roast and ground coffee the same as the temperature of the heat exchange fluid and has a particle size distribution such that: will be somewhat higher because milling of coffee particles to 0622 (a) from about 90% to 100% by weight is retained on produce flakes tends to increase the roll Surface temperature. a No. 30 U.S. Standard Sieve, Accordingly, determination of the temperature of the 0623 (b) from about 51% to 89% by weight is retained on exchange fluid necessary to maintain any specific roll Surface a No. 16 U.S. Standard Sieve, and temperature will depend upon several factors, such as the kind 0624 (c) from about 20% to 50% by weight is retained on of metal the roll is made of the roll wall thickness, the speed a No. 12 U.S. Standard Sieve. of operation of the roll mills, and the nature of the heat 0625. The extractability advantage for flaked coffee pre exchange fluid employed. pared by utilizing a “coarse' size grind feed to the roll milling 0631. To produce the thin-flaked roast and ground coffee operation decreases rapidly as flake thickness increases of the eighth group of embodiments, it is important that the beyond 0.20 mm. Stated differently, as flake thickness roll surface temperature be less than about 40°C., preferably increases, the particle size of the feed to the roll mill becomes between about 5° C. to 30° C. less significant in increasing the extractability of flaked cof fee. 4. Static Gap 0626 Typical grinding equipment and methods for grind 0632. As used herein, the term “static gap' represents that ing roasted coffee beans are described in detail in, for distance separating the two roll mills along the line of nip example, Sivetz & Foote, “Coffee Processing Technology’. while at rest and is typically measured in mm or mils. A 1963, Vol. 1, pp. 239-250, herein incorporated by reference. special condition of roll spacing is “Zero static gap' which is used herein to indicate that the two rolls are in actual contact 2. Roll Pressure or Force with each other along the line of nip when the roll mills are at 0627 Roll pressure will also influence the nature of the rest. As roast and ground coffee is fed into the roll mills and roast and ground coffee flakes obtained by the process of the drawn through the nip, it causes the rolls to deflect an amount eighth group of embodiments. Roll pressure is measured in which is dependent upon the roll peripheral speed, roll pres pounds per inch of nip. In metric units it is measured in sure, and coffee feed rate. Accordingly, the thin-flaked coffee kilomewtons/meter of nip. Nip is a term used in the art to of the eighth group of embodiments can be made even when define the length of surface contact between two rolls when the roll mills are set at Zero static gap. Because of the deflect the rolls are at rest. To illustrate, it can be thought of as a line ing action of the coffee feed as it passes through the roll mill, extending the full length of two cylindrical rolls and defining the static gap setting should be less than the desired flake the point or line of contact between two rolls. thickness. Suitable static gap settings range from 0 (i.e. from 0628. To produce thin-flaked roast and ground coffee of a Zero gap setting) up to about 0.1 mm. Preferably, the gap high extractability and in high yield, the roll mill should be setting ranges from about 0 to about 0.1 mm. operated at a static gap setting of less than about 0.1 mm, a roll 0633. In the most preferred method of practice, a zero peripheral speed of from about 150 meters/min. to about 800 static gap spacing of the roll mills is employed. Differential meters/min., a roll surface temperature of below about 40°C., roll peripheral surface speeds are to be strictly avoided when and at a pressure of about 100 kilomewtons/meter to about 400 the roll mills are set for Zero static gap operation. Contact kilomewtons/meter of nip, and wherein the rolls of said mill along the line of nip between rolls operating at differential have a roll diameter of at least about 15 cm. In general, peripheral Surface speeds can cause severe physical damage operable feed rates are directly related to the roll pressure. to the roll mill. Differential roll peripheral surface speeds can Thus, higher roll pressure allows a higher feed rate to the roll be utilized, however, with static gap spacings exceeding mill to produce a flake of specific thickness for otherwise about 0.05 mm. equivalent operating conditions of the roll. The disadvantages of using higher roll pressures are simply mechanical, e.g. 5. Moisture Content more expensive equipment is needed to produce higher roll 0634. In producing consumer-acceptable flaked roast and pressures. Conversely, at low roll pressures, the feed rate can ground coffee, it is important that the average flake moisture drop below commercially desirable rates. content be from about 2.5% to 9.0% by weight, with 3.5% to 7.0% being preferred. Since the moisture level of the coffee 3. Roll Surface Temperature particles is not significantly affected by the flaking operation, 0629 Control of the surface temperature of each roll is the moisture level of the thin-flaked coffee product herein can believed to be important to the provision of thin-flaked roast be controlled by controlling the moisture content of the roast and ground coffee of high extractability. Roll surface tem and ground coffee feed. Consequently, the average moisture perature refers to the average surface temperature of each roll content of the roast and ground coffee particles to be flaked of the roll mill. The rolls can be operated at differential should be within the range of from about 2.5% to about 9.0%. operating temperatures. However, operation under conditions Flaked roast and ground coffee particles having lower mois of differential roll temperatures is not preferred. ture levels tend to be more brittle, which leads to the produc 0630. The surface temperature of each of the respective tion of an undesirably high level of fines. rolls can be controlled by a heat exchange fluid passing through the inner core of the rolls. Generally, the fluid, which 6. Feed Rate is most often water, is heated or cooled and passed through the 0635. The feed rate to the roll mill is that amount of mate inside of the rolls. The result is that the roll surface which is rial per hour per meter of nip which is fed into the nip area. usually a smooth, highly polished steel Surface, is subjected to The throughput rate is the amount of material per hour per temperature control by means of heat transfer. Of course, in meter of nip that actually passes through the roll mill. When actual operation the Surface temperature will not be exactly the feed rate exceeds the throughput rate, a condition occurs US 2014/0370181 A1 Dec. 18, 2014 42 which is referred to in the art as "choke feeding'. Conversely, the range of from 15 to 76 cm. Examples of suitable mills when the feed rate falls below the theoretical throughput rate, which can be adapted in known manner to operation within the feed rate and throughput rate are the same. This condition the parameters defined hereinbefore include any of the well is referred to in the art as “starve feeding. Starve feeding known and commercially available roll mills, such as those offers the particular process advantages Such as increased sold under the tradenames of Lehmann, Thropp, Ross, Farrell process control, increased equipment life, and increased pro and Lauhoff. cess flexibility and is, therefore, the more suitable mode of operation in the method of the eighth group of embodiments. B. Screening 0641 After the roast and ground coffee feed has been 7. Roll Peripheral Surface Speed flaked by being passed through the roll mill, it is important 0636 Control of the peripheral surface speeds of the rolls that the thin-flaked coffee produced goes through a sizing is believed to be important to the provision of the thin-flaked operation so as to insure that the thin-flaked coffee product roast and ground coffee herein. The roll peripheral surface has a particle size distribution as described below. Impurities speed is measured in meters per minute of roll Surface cir in the roast and ground coffee feed to the roll mill typically cumference which passes by the nip. Generally, the roll mill produce oversized flakes which can be readily removed by the should be operated at a roll speed of from about 150 meters/ sizing operation. And too, since operation of the roll mill min. to 800 meters/min., preferably from about 200 meters/ within the parameter ranges given above can result in a sec min. to about 700 meters/min. ondary grinder effect, the sizing operation can serve to 0637 For a given set of roll mill operating conditions, the remove an undesirable level of fine particles. throughput rate, the roll peripheral Surface speed and the 0642 A wide variety of suitable sizing methods and appa thickness of the flaked coffee produced are closely related. In ratus are known in the art (see, for example, “Perry's Hand the production of flaked coffee of a specified thickness, the book for Chemical Engineers’, McGraw-Hill Book Co., pp. throughput rate is directly related to the roll peripheral surface 21-46 to 21-52, incorporated herein by reference). For speed. Thus, an increase in the roll peripheral Surface speed example, the thin-flake coffee can be effectively screen-sized allows an increase in the throughput rate in producing flakes by dropping the thin-flaked coffee particles from a hopper, of specified thickness. When a constant throughput rate is chute or other feeding device into a mechanically vibrating maintained (e.g. by controlling the feed rate), higher roll screen or into a multiple sieve shaker Such as those marketed peripheral Surface speeds produce thinner flakes and con by Newark Wire Cloth Company and the W. S. Tyler Com versely, lower roll peripheral surface speeds produce thicker pany. Typically, the sizing operation separates the flaked cof flakes. If the throughput rate is increased, the roll peripheral fee of various particle sizes into desired size fractions in less Surface speed should be increased to maintain the production than one minute. Such equipment typically have exit or dra of flakes of a desired thickness. woff ports which allow the withdrawal of oversize or plus 0638. While peripheral surface roll speeds have been set material. Such drawoff parts also allow withdrawal of fines forth in connection with operation of a roll mill to provide (i.e. through a No. 30 U.S. Standard Sieve) so as to achieve a thin-flaked coffee of improved extractability, it will be appre sieve analysis or particle size distribution Such that a thin ciated that optimal speeds will be determined in part by the flaked coffee product is produced such that about 30% to other roll mill conditions, such as the size of the rolls about 90% by weight passes through a No. 30 U.S. Standard employed, the static gap setting, etc., as well as the physical Sieve. and organoleptic properties desired in the flaked product. 0643. In preparing the coffee compositions as defined in the Summary of the Invention, the coffee in the coffee com 8. Roll Diameters position 110/130 and beverage material 120 as shown in FIGS. 1A, 1B, and 1C may have various cell structures. As 0639. The process of the eighth group of embodiments can previously mentioned, flaked roast and ground coffee is con be practiced with the aid of any of a variety of roll mills of templated in the present invention. The ninth group of various roll diameters capable of subjecting roast and ground embodiments according to the present invention provides coffee to mechanical compressing action and adapted to the roast and ground coffee in the form of high-sheen flakes and adjustment of roll pressure, roll speed and roll temperature. having improved extractability. A process for preparing Suitable mills are those having two parallel rolls so that coffee flaked roast and ground coffee of high sheen and improved particles passed between the rolls are crushed or flattened into extractability by passing roast and ground coffee through a flakes. Normally, smooth or highly polished rolls will be roll mill operating at differential speeds and temperatures is employed as they permit ready cleaning; other rolls can, also disclosed. The process comprises: passing roast and however, be employed if the desired flaking effects can be ground coffee through a roll mill wherein a first roll has a obtained. peripheral surface speed of 30 ft./min. to 850 ft./min. and a 0640. In the selection of suitable roll mill equipment atten surface temperature of from 0°F. to 140°F. and a second roll tion should be given to the diameters of rolls. The diameter of has a peripheral Surface speed corresponding to from 2 to 8 the roll mills, while it controls the angle of entry into the nip times that of the first roll and a surface temperature of from which in turn affects flake thickness and bulk density, is not 150°F. to 300°F.; and removing from said roll mill roast and critical perse. While rolls smaller than about 15 cm in diam ground flakes of high sheen and extractability. eter can be employed to flake coffee, roll mills having a 0644. In the ninth group of embodiments, desirable orga diameter of less than about 15 cm tend to hamper passage of noleptic and physical appearance properties in a roast and the coffee through the mill by a churning effect which ground coffee product can be realized by providing the prod decreases throughput and efficiency. If available, roll mills of uct in the form of high-sheen flakes prepared by roll milling even as high as 122 cm in diameter should be suitable. How under conditions of differential surface roll speeds and dif ever, good results are obtained from mills having diameters in ferential temperatures. In its product aspect, the ninth group US 2014/0370181 A1 Dec. 18, 2014
of embodiments resides in high-sheen roast and ground cof ground flaked having a flake thickness of between 0.008 and fee flakes characterized by a reflectance value of at least 35 0.025 in. and having a reflectance value of at least 35 reflec units as determined by reflectance of a laser beam having a tance units, said reflectance units representing reflectance by wave length of 6328 A. coffee flakes of light from 0.88 helium/neon gas laser beam of 0645. In its process aspect, the ninth group of embodi 6328 Angstrom wavelength, calibrated against reflectance ments provides a method for producing flaked roast and values of 2 and 89 units, respectively, for the Federal Bureau ground coffee of high sheen and improved extractability by of Standards Paint Chips 15042 and 11670; and from 20 to (1) passing roast and ground coffee through a roll mill having 90% of non-flaked roast and ground coffee. a first roll operating at a peripheral surface speed of from 30 0651. In more specific examples under this aspect, the ft/min. to 850 ft./min. and at a surface temperature of from 0° roast and ground coffee flakes comprise from 25 to 60% by F. to 140°F. and a second roll operating at a peripheral surface weight and the non-flaked roast and ground coffee comprises speed of from 2 to 8 times that of the first roll and a surface from 40 to 75%. For example, such roast and ground coffee temperature of from 150°F. to 300°F.; and (2) removing from flakes may be characterized by a reflectance value of from 40 said roll mill, roast and ground flakes of high sheen and to 60 reflectance units. extractability. 0652) Another aspect of the ninth group of embodiments 0646. The ninth group of embodiments relates to roast and provides for a coffee composition for use in a beverage unit ground coffee and to a method for preparing same. More and method thereofas defined in the Summary of the Inven particularly, it relates to roast and ground coffee in the form of tion, wherein the coffee composition comprises roast and high-sheen flakes which exhibit improved extractability and ground coffee flakes of high sheen and extractability, made to a process for preparing same. from a process which comprises: passing roast and ground 0647. In connection to the background of the ninth group coffee through a roll mill having a first roll operating at a of embodiments, roast and ground coffee, i.e. coffee obtained peripheral surface speed of from 30 to 850 feet perminute and by the grinding of roasted coffee beans, has for the most part at a surface temperature of from 0°F. to 140°F. and having a existed in the conventional form known to all consumers. second roll operating at a peripheral Surface speed of from 2 While considerable effort has been expended in the area of to 8 times that of the first roll and a surface temperature of “instant coffees to simulate the organoleptic and physical from 150°F. to 300°F.; and removing from said roll mill said characteristics of roast and ground coffee, little relative effort roast and ground coffee flakes. has been directed to altering the fundamental physical char 0653. In more specific examples under this aspect, said acteristics of conventional roast and ground coffee. For second roll has a peripheral surface speed of from 3 to 5 times example, U.S. Pat. No. 1,903,362 (issued Apr. 4, 1933 to that of said first roll; or said second roll has a peripheral McKinnis), U.S. Pat. No. 3,615,667 (issued Oct. 26, 1971 to surface speed of from 3 to 5 times that of said first roll and a Joffe), and U.S. Pat. No. 3,660,106 (issued May 2, 1972 to surface temperature of from 180° F. to 220° F. McSwiggin et al.) disclose coffee products in the form of 0654. In more specific examples under this aspect, said flakes, while U.S. Pat. No. 3,713,842 (issued Jan. 30, 1973 to first roll has a peripheral surface speed of from 250 to 650 feet Lubsen et al.) describes panagglomerated roast and ground per minute and a surface temperature of from 50° to 100°F. coffee of unique appearance. Similarly, U.S. Pat. No. 3,801, For example, said second roll has a peripheral Surface speed 716 (issued Apr. 2, 1974 to Mahlmann et al.) describes a of from 3 to 5 times that of said first roll and a surface process of compressing and granulating roast coffee beans for temperature of from 180° F. to 220° F. the purpose of developing unique physical and/or organolep 0655. In more specific examples under this aspect, the roll tic properties. While these patents illustrate prior art efforts to mill has a roll pressure of from 1500 to 3500 pounds per inch alter the conventional appearance of roast and ground coffee, of nip. For example, the roll pressure is from 2000 to 3000 the great bulk of the roast and ground coffee presently com pounds per inch of nip. mercialized exists in its appearance aspects in relatively non 0656. The ninth group of embodiments as described above distinctive form. An especially distinctive and desirable will be further described in the following paragraphs and appearance is, however, considered preferable by Some con exemplified in Examples 30-34. Sumers. Thus, it would be desirable to provide a roast and 0657. As used in the ninth group of embodiments, the ground coffee product combining desirable organoleptic terms flaked roast and ground coffee and roast and ground properties, improved extractability and an especially distinc coffee flakes are used interchangeably to refer to roast and tive and pleasing physical appearance. ground coffee in the form of flakes. 0648. It is an object of the ninth group of embodiments to 0658. The flaked roast and ground coffee of the ninth provide a roast and ground coffee product exhibiting desir group of embodiments can be formed by Subjecting conven able organoleptic and physical properties and a process for tional roast and ground coffee to the mechanical pressures of providing same. a roll mill operating under conditions of differential roll speed 0649. Another object of the ninth group of embodiments is and temperature. The roast and ground coffee is passed the provision of a roast and ground coffee product in a par through the roll mill which comprises a pair of parallel ticularly unique and pleasing physical form attractive to some smooth or highly polished rolls and which crushes and flat COSU.S. tens the coffee particles into flakes. The differential-speed 0650 One aspect of the ninth group of embodiments pro and -temperature conditions of the mill cause the flakes to vides for a coffee composition for use in a beverage unit and take on a high sheen or glistening appearance which is pre method thereofas defined in the Summary of the Invention, ferred by some consumers. The differential-speed and -tem wherein the coffee composition comprises a roast and ground perature conditions also effect a disruption of the cellular coffee composition comprising from 10 to 80% by weight of structure and the coffee particles in Such a manner as to the composition of roast and ground coffee in the form of provide a higher level of extractability than generally flakes of high sheen and extractability, said roasted and obtained from roast and ground coffee flakes. The provision US 2014/0370181 A1 Dec. 18, 2014 44 of roast and ground coffee flakes of high sheen and improved result that the flakes are readily broken with the formation of extractability is believed to depend upon the control of certain appreciable quantities of undesirable powder or fines. Exces processing parameters including the peripheral Surface sive speed of the faster roll also tends to promote increases in speeds of the rolls and the temperatures of the rolls. These and the surface temperature of the rolls with the result that flavor other processing variables are described in detail hereinafter. degradation is obtained. As is described hereinafter, roll sur 0659. The flaked roast and ground coffee of the ninth face temperatures in excess of 300°F. are undesirable from group of embodiments is provided in the form of high-sheen the standpoint of product flavor degradation and, accordingly, flakes of improved extractability largely as the result of the roll speeds tending to promote the attainment of Such tem employment of differential roll speed which hereinafter peratures and adverse flavor effects are desirably avoided. refers to the employment of roll mill conditions whereby the Best results are obtained when the differential is from 3:1 to rolls operate at different roll peripheral surface speeds, i.e., 5:1. one roll is allowed to operate at a speed greater than that of the 0663 While peripheral surface roll speeds and speed dif other roll. The peripheral surface speed of the rolls is mea ferentials have been set forth in connection with operation of sured in feet per minute of surface circumference which a roll mill to provide high-sheen flakes of improved extract passes by the nip of the rolls. It is believed that a high sheen ability, it will be appreciated that optimal speeds will be or glazed appearance can be provided on at least one Surface determined in part by the size of the rolls employed and the of coffee flakes by operating a first roll within the range of physical and organoleptic properties desired in the flaked from 30 to 850 ft./min. and a second or faster roll at a speed product. with respect to the slower roll corresponding to the ratio of 0664. The roll-mill surface temperature, measured in from 2:1 to 8:1. degrees Fahrenheit, refers to the average surface temperature 0660. The employment of differential roll speeds permits of each roll of the roll mill. Control of the surface temperature individual coffee particles to be glazed or shined by a rela of each roll has been found to be important to the provision of tively faster moving smooth roll. The slower of the rolls high-sheen roast and ground coffee flakes of improved allows the particles to be held momentarily onto the roll and extractability. Moreover, the temperature of each roll has sufficiently long for the faster roll to effect a glazing or been found to be closely tied to and correlated with the Smoothing operation on one side of each flake. The resulting peripheral surface speeds of the respective rolls. For example, high-shear effect enables the provision of flakes which it is believed that the faster of the two rolls may also be exhibit a distinctive and high-sheen appearance and which are operated at a surface temperature higher than that of the characterized by extensive cell disruption and high extract relatively slower roll. ability. 0665. In general, higher roll surface temperatures produce 0661 The slower of the two rolls will normally be oper thinner flakes of roast and ground coffee which typically have ated at a speed of from 30 to 850 ft./min. A roll speed slower high fines levels and increase the propensity for flavor degra than about 30 ft./min. tends to be impractical from the stand dation. On the other hand, lower roll surface temperatures point of desired product throughput. The flakes also tend to be produce relatively thicker flakes with little or no flavor deg thicker than those normally considered to be consumer radation. High-sheen roast and ground flakes of high extract acceptable. A roll speed greater than about 850 ft/min.tends ability and desirable thickness can be produced in an efficient to produce flakes which are thin and which contain more fines manner and at high throughput by employing a roll Surface than might be considered acceptable. Moreover, high periph temperature for the slower roll in the range of from 0°F. to eral Surface speeds promote frictional temperature increases 140°F. Temperatures less than 0° F. are undesirable because which can alter and degrade the flavor of the roast and ground expensive cooling systems must be employed and at Such low flakes. The employment of a peripheral roll speed for the temperatures the flake thickness tends to be greater than 0.025 slower roll of from 250 to 650 ft./min. permits the attainment inches; consequently, the flakes are thicker than those nor of desirable throughput rates and enables the manufacture of mally considered consumer acceptable. Additionally, attem high-sheen flakes having a thickness in a preferred range of peratures less than 0°F, the resultant coffee flakes are very from 0.008 to 0.025 inch. Thus, a preferred range of periph brittle and have a tendency to break during Subsequent pro eral roll speed in the case of the slower roll is from 250 to 650 cessing and packaging. This is undesirable because breaking ft/min. of brittle flakes results in a change in product bulk density 0662. The peripheral roll speed of the second and rela which may affect the consumer acceptability of the coffee tively faster roll is an important parameter in the manufacture flakes produced. Such weak flakes often have bulk densities of high-sheen flakes of improved extractability. Normally, the not within the range of consumer acceptable flake bulk den faster roll will be operated at a speed with respect to the sities. slower roll corresponding to the range of from 2:1 to 8:1. The 0666. It is preferred that the surface temperature of the faster roll affects the shining or glazing of individual com slower roll be within the range of from 50° F. to 100°F. When pressed or flaked particles as they are momentarily held by the roll Surface temperatures within this range are employed the relatively slower roll. If the faster roll is operated so slow as to majority of the resultant coffee flakes exhibit high sheen, have provide a speed differential of less than 2:1, the flaked par a thickness generally considered consumer acceptable, and ticles do not take on the distinctive and desirable sheen which combine high structural integrity and little or no flavor deg characterizes the product of the ninth group of embodiments. radation. The shearing action provided by the requisite speed differen 0667 The roll surface temperature of the faster roll is tial is lacking where this minimum differential is not main believed to have a material effect on the nature of the flakes tained. Conversely, the speed of the faster roll should not produced by the process of the ninth group of embodiments. exceed a rate corresponding to a differential of about 8:1. A In order to obtain a desirable high-sheen effect, it is believed differential peripheral roll speed of greater than 8:1 causes the that the faster roll of the two rolls of the roll mill should also flakes to be thinner and to contain excessive fines with the be operated at a higher Surface temperature than the slower US 2014/0370181 A1 Dec. 18, 2014
roll. Roast and ground coffee flakes of high sheen and extract capable of Subjecting roast and ground coffee to mechanical ability are produced when the surface temperature of the compressing action and adapted to the adjustment of pres faster roll is in the range of from 150° F to 300° F. If the sure, roll speed and temperature. Suitable mills are those temperature of the faster roll is such that the temperature is having two parallel rolls So that coffee particles passed less than about 150°F., the flakes tend to have little plasticity between the rolls are crushed or flattened into flakes. Such and do not take on the desired and characteristic sheen. More mills will permit independent adjustment or variation of over, a low yield of roast and ground coffee flakes is obtained speed and temperature parameters such that a relatively faster as the flakes tend to be grabbed by the faster roll and torn into and hotter roll can effect shining of individual flakes of roast fragments. A roll surface temperature for the faster roll in and ground coffee. Normally, smooth or highly polished rolls excess of 300°F. is also undesirable from the standpoint of will be employed as they permit ready cleaning; other rolls flavor degradation or over-heating the product. Preferably, the can, however, be employed if the desired flaking and high faster roll is operated at a temperature of from 180°F. to 220 sheen effects can be obtained. F. which provides best results from the standpoint of sheen, 0673. The diameter of the roll mills, while it controls the yield and flavor results. angle of entry into the nip which in turn affects flake thickness 0668. The surface temperature of each of the respective and bulk density, is not critical perse. While rolls smaller than rolls can be controlled in known manner. This is accom 6 inches in diameter can be employed to nip fine grind cof plished by control of the temperature of a heat exchange fluid fees, roll mills having a diameter of less than about 6 inches passing through the inner core of the rolls. Generally, the tend to hamper passage of the coffee through the mill by a fluid, which is most often water, is heated or cooled and churning effect which decreases throughput and efficiency. passed through the inside of the rolls. The result is that the roll Best results will be obtained from mills having diameters in Surface which is usually a smooth, highly polished Steel Sur the range of from 6 to 30 inches. Examples of suitable mills face, is subjected to temperature control by means of heat which can be adapted in known manner to operation within transfer. Of course, in actual operation the Surface tempera the parameters defined hereinbefore include any of the well ture will not be exactly the same as the temperature of the heat known and commercially available roll mills Such as those exchange fluid and will be somewhat higher because milling sold under the tradenames of Lehmann, Thropp, Ross, Farrell of coffee particles to produce flakes tends to increase the roll and Lauhoff. surface temperature. This is especially true with respect to the 0674. The process of the ninth group of embodiments can faster roll which constantly slides or rubs over the surface of be readily practiced by simply passing roast and ground cof coffee flakes. Accordingly, determination of the temperature fee into a roll mill operating within the parameters hereinbe of the exchange fluid necessary to maintain any specific roll fore defined and removing the high-sheen flakes which are Surface temperature will depend upon several factors such as dropped from the rolls. Normally, a chute or other feeding the kind of metal the roll is made of the roll wall thickness, device will be employed to drop roast and ground coffee the speed of operation of the roll mills, and the nature of the particles into the nip of the roll mill, as for example, by heat-exchange fluid employed. dropping the coffee particles from a hopper or by vibrating a 0669 Roll pressure will also influence the nature of the falling cascade of particles into the nip. roast and ground coffee flakes obtained by the process of the 0675. The feed rate into the roll mill, of the roast and ninth group of embodiments. ground coffee to be flaked, is not critical. Either choke feed 0670 Roll pressure is measured in pounds per inch of nip. ing or starve feeding can be employed as long as the previ Nip is a term used in the art to define the length of surface ously discussed processing variables are operated within their contact between two rolls when the rolls are at rest. To illus prescribed ranges. Choke feeding is defined as having excess trate, it can be thought of as a line extending the full length of amounts of coffee settling on the roll mills waiting to pass two cylindrical rolls and defining the point or area of contact through the nip. It is the opposite of starve feeding. between two rolls. 0676 In further regard to the feeding rate, while either 0671 To produce flaked roast and ground coffee of high starve feeding or choke feeding can be employed, starve sheen and extractability and in highyield, roll pressure should feeding is preferred because of particular process advantages be within the range of from 1500 to 3500 lbs./inch of nip and offered by starve feeding Such as greater economic efficiency, preferably within the range of from 2000 to 3000 lbs./inch of increased equipment life and increased process flexibility. nip. If pressures much less than 1500 lbs./inch of nip are 0677. The process of the ninth group of embodiments has employed, the resulting flakes do not take on a high-sheen applicability to a variety of roast and ground coffee products appearance. Moreover, any flakes that are produced are much including those which may be classified for convenience and thicker than 0.025 inches and consequently the flakes are not simplification as low-grade, intermediate grade, and high normally considered consumer acceptable. On the other grade coffees. Suitable examples of low-grade coffees hand, if pressures in excess of 3500 lbs./inch of nip are include the natural Robustas such as the Ivory Coast Robustas employed the roast and ground coffee flakes tend to be thin and Angola Robustas; and the Natural Arabicas such as the and readily fractured because of the differential speed with natural Perus and natural Ecuadors. Suitable intermediate the result that a low yield of large flakes and an appreciable grade coffees include the natural Arabicas from Brazil such as amount of coffee fines is obtained. Additionally, at pressures Santos, Paranas and Minas; and natural Arabicas Such as in excess of 3500 lbs./inch of nip the roll friction produces Ethiopians. Examples of high-grade coffees include the excessive amounts of heat which as hereinbefore related also washed Arabicas such as Mexicans, Costa Ricans, Colombi tends to produce thin flakes of impaired flavor characteristics. ans, Kenyas and New Guineas. Other examples and blends Best results are obtained when the roll pressure is within the thereofare known in the art and illustrated for example in U.S. range of from 2000 to 3000 lbs./inch of nip. Pat. No. 3,615,667 (issued Oct. 26, 1971 to Joffe). 0672. The process of the ninth group of embodiments can 0678. The roast and ground coffee suitable for use in the be practiced with the aid of any of a variety of roll mills preparation of the high-sheen flakes of the ninth group of US 2014/0370181 A1 Dec. 18, 2014 46 embodiments include those conventionally prepared by (B2M Photocell, International Rectifier Corp.) is mounted in known grinding means into “regular”, “drip', or “finegrinds the circle of the inner mount immediately adjacent the pro as these terms are used in the art. The standards of these grinds truding fiber optic sensor element. The impulse from the are suggested in the 1948 Simplified Practice Recommenda photocell is passed to an amplifier and then to an electronic tion by the U.S. Department of Commerce (see Coffee Brew recorder. ing Workshop Manual, page 33, published by the Coffee 0683. A helium-neon gas laser unit (Spectraphysics Brewing Center of the Pan American Bureau). The particle Model 155, Spectra-Physics, Mountain View, Calif.) is size of the feed is not, however, critical and can be varied mounted vertically on the lid in an abutting relationship to the widely. The choice of grind will in part depend upon the outside mount. The laser beam, 0.88 mm. diameter and 6328 particle size distribution and bulk density desired in the flaked A wavelength, is directed at a 90° angle through and into the product. enclosure and is impinged upon the sample flake. The dis 0679 The roast and ground coffee suitable for manufac tance between the laser beam and the platform is 25/16 inches. ture into high-sheen flakes can be roasted to any of the roast The flake surface is scanned by manual adjustment of the colors generally recognized in the coffee arts. Thus, the light platform to locate the point of highest reflectance as detected and dark roasts known in the art can be suitably employed. In by the fiber-optic sensor. The electronic signal from the pho actual practice, dark roasts are preferred inasmuch as the tocell is amplified and registered on a 0-to-100 scale of an high-sheen effect is particularly evident against the darker electronic recorder (Honeywell Electronik 193, Honeywell background of a dark-roast product and the greatest impact or Inc., Minneapolis, Minn.). A Zero reading is obtained when visual impression can be realized. the laser unit is off, i.e. there is no reflected light. 0680. As previously stated in the ninth group of embodi 0684. The apparatus is calibrated by reference to standa ments, the flaked roast and ground coffee product prepared by rized reflective surfaces. A standardized paint chip of dark the process of the ninth group of embodiments is distinctly blue color and hue (No. 15042, Federal Standard 595, 1961 different in appearance from the conventional roast and Edition, available from National Bureau of Standards, Wash ground and flaked roast and ground coffee products described ington, D.C.) is utilized as a standard reflecting Surface and in the art. The distinctive physical appearance can be quanti the recorder is adjusted so as to provide a reading of two on fied by resort to reflectance measurement techniques and the 0-to-100 recorder scale. Similarly, a standardized paint calibration against standardized reflecting Surfaces. chip of beige color and hue (No. 11670, Federal Standard 0681. A suitable technique for measuring the reflectance 595, 1961 Edition, available from National Bureau of Stan of the roast and ground coffee flakes produced by the process dards, Washington, D.C.) is utilized as a standard for calibra of the ninth group of embodiments is based upon the principle tion in the higher range of the scale, the recorder being that high-sheen Surfaces reflect a greater proportion of inci adjusted so that a reading of 89 is obtained. The reflectance dent light than relatively dull Surfaces. Based upon measure values for the two standard paint chips are measured alter ment of the light reflected by the surfaces of flaked coffee nately and the recorder is adjusted until readings of 2 and 89 particles and comparison with the light reflected by standard are obtained. The test coffee flake is then impinged with the surfaces, a reflectance value for flaked coffee can be readily standardized light source described hereinbefore and a read obtained. ing of reflectance value is recorded on the 0-to-100 scale. 0682. In actual practice, the reflectance value of flaked 0685 Since coffee flakes do not provide a perfectly planar coffee particles can be determined by measuring the light reflective surface and, thus, a degree of light scattering is reflected by a single flake particle impinged with light from a observed, an average of three readings is taken to minimize standardized source. The following method and apparatus reflectance variations from a single flake. An initial reading is can be employed for this purpose. A random sample flake, of recorded at a first flake orientation, referred to as the Zero a size which permits handling, is placed on a movable plat degree orientation. A second reading is taken at the position form or table within a light-tight enclosure. The table is obtained by rotating the flake 120° clockwise from the first adjustable for forward, backward and lateral movement by orientation (the 120° orientation) and a third reflectance read means of inner tracks and other controls. Suitable apparatus ing is taken at the orientation obtained by rotating the flake for this purpose is a conventional thin-film Scanner unit 120° clockwise from the second orientation (referred to as the equipped with movable scanner platform (American Instru third orientation). At each orientation, the flake is manually ment Company, Div. of Travenol Laboratories, Inc., Silver scanned by the larger beam and the highest reflectance read Spring, Md., Cat. No. 4-7410). The lid of the light-tight ing at that orientation is recorded. The average of the three enclosure (thin-film Scanner unit) is provided with a light port readings represents the reflectance value of the coffee flake. (hole) by means of which a light beam from an outside Source The process of measuring the reflectance value of individual is allowed to impinge at a 90° angle upon the sample placed flakes is repeated a minimum offive or six times or as a means on the platform inside the enclosure. The lid is provided with of minimizing any variations in flakes and to ascertain an an outside mounting block having a Superimposed light port average value which is taken as the reflectance value for the and means for mounting a fiber optic sensing element. An particular batch of coffee tested. inside mount, a plate having a 3-inch diameter hole and posi 0686. As used in the ninth group of embodiments and tioned on the inside of the lid such that the light passes claims 27 and 28, reflectance value, expressed as arbitrary through the center of the three-inch hole is provided for reflectance units, represents the reflectance by coffee flakes of mounting of a photocell. The fiber optic sensor (Edmund light from a 0.88 mm. helium/neon gas laser beam of 6328A Scientific, duPont Crofon /8-inch light guide) is mounted in wavelength, calibrated against reflectance values of 2 and 89 the outside mount behind the light port and inwardly toward units, respectively, for Federal Bureau of Standards Paint the light beam at a 45° angle. The tip of the sensor element Chips 15042 and 11670. protrudes into the three-inch circle of the inner mount and 0687. The flaked roast and ground coffee of the ninth picks up reflected light from the sample. A selenium photocell group of embodiments is characterized by a reflectance value US 2014/0370181 A1 Dec. 18, 2014 47 of at least about 35 reflectance units. A roast and ground 0692. Other important advantages of the ninth group of coffee product which is comprised of flakes which have a embodiments are the provision of high-sheen flakes of high Surface providing 35 reflectance units is readily appreciated structural integrity and with little or no flavor degradation. as exhibiting a distinct, high-sheen orglistening effect. Below The desirability of flakes of high structural integrity (i.e., about 35 reflectance units, a high-sheen effect is not observed. physical strength and resistance to attrition or breakage dur As used herein, high-sheen flakes are characterized by a ing packing) is important because large percentages of broken reflectance value of at least 35. flakes can change the produce bulk density and present unap 0688. While reflectance values above about 60 are desir pealing appearance and cause cup sediment in the brew. Mini able from the standpoint of the visual effect and distinctive mized coffee flavor degradation is, of course, important in ness, such values tend to be difficult to attain. High-sheen respect to consumer preference for a coffee product. flakes of reflectance value 40 to 60 can be conveniently and 0693. In preparing the coffee compositions as defined in economically produced by the process described herein and the Summary of the Invention, the coffee in the coffee com combine readily recognizable sheen and are, thus, preferred position 110/130 and beverage material 120 as shown in herein. FIGS. 1A, 1B, and 1C may have various cell structures. As 0689. The roast and ground coffee flakes of the ninth previously mentioned, flaked roast and ground coffee is con group of embodiments can be packaged and utilized in the templated in the present invention. The tenth group of preparation of a brew or extract in known manner. When the embodiments according to the present invention provides a flakes are produced by the milling process herein described, a fast roasted coffee that exhibits increased brew strength and content offines will normally be present and depending upon darker cup color with desirable brew acidity. The tenth group the particular extraction method employed a greater or lesser of embodiments relates to roast and ground and flaked coffee amount of cup sediment may be observed. According to pre products that have been fast roasted. This application particu ferred practice, the high-sheen flakes will be employed in larly relates to fast roasted coffees that provide a darker cup combination with conventional roast and ground coffee. Nor color and improved flavor strength, yet with a desirable level mally, flake-containing compositions will comprise from of brew acidity. about 10 to about 80% by weight of the composition of the 0694. In the tenth group of embodiments, roast and ground high-sheen flakes and from about 90 to about 20% conven or flaked coffee products provide more brew strength and cup tional, i.e., non-flaked, roast and ground coffee. Thus, the color at lower levels of brews solids. These coffee products content of high-sheen flakes can be varied depending upon contain darker faster roasted coffee that is predominantly the amount of sheen desirably provided in the product and high acidity-type coffee that provide, when brewed appropri upon the desired contribution of the flakes to cup solids and ate conditions, a consumable coffee beverage having: (1) a flavor. The balance of the composition, i.e., conventional brew solids level of from about 0.4 to about 0.6%; (2) a roast and ground coffee, can be controlled, if desired, to Titratable Acidity of at least about 1.52; (3) a brew absor diminish its contribution to cup Solids in recognition of the bance of at least about 1.25, provided that when the Titratable enhanced extractability of the flakes of the ninth group of Acidity is in the range of from about 1.52 to about 2.0, the embodiments. brew absorbance is equal to or greater than the value defined 0690. A preferred composition combining a distinctive by the equation: physical appearance with high extractability and desirable 1.25+0.625x(2.0-TA) organoleptic properties comprises from about 25 to 60% of (0695 where TA is the Titratable Acidity. flakes exhibiting a reflectance value of from 40 to 60; and 0696. The tenth group of embodiments relates to a roast from about 40 to about 75% of conventional roast and ground and ground or flaked coffee product which provides more coffee. brew strength and cup color, yet with a desirable level of brew 0691 An important aspect of the process of the ninth acidity. This coffee product has a Hunter L-color of from group of embodiments is the provision of roast and ground about 13 to about 19 and comprises from about 50 to 100% coffee flakes of improved extractability. It is believed that the high acidity-type coffee, from 0 to about 30% low acidity employment of differential roll-speed and temperature con type coffee, and from 0 to about 50% moderate acidity-type ditions during flake rolling provides an enhancement in coffee. This coffee product, when brewed under appropriate extractability of the resulting flakes over that normally conditions, is capable of providing a consumable coffee bev encountered in the flaking of roast and ground coffee. This erage having: enhancement is manifested by higher brew strength per (0697 (1) a brew solids level of from about 0.4 to about weight of coffee employed in making a brew or infusion and 0.6%; is especially desirable where flaked decaffeinated product is (0698 (2) a Titratable Acidity of at least about 1.52: desired. As is known in the art, the removal of caffeine from 0699 (3) a brew absorbance of at least about 1.25, pro coffee products frequently is accomplished at the expense of vided that when the Titratable Acidity is in the range of from the removal of certain other desirable components that con about 1.52 to about 2.0, said brew absorbance being equal to tribute to flavor. The tendency of decaffeinated products to be or greater than the value defined by the equation: either weak or deficient in flavor has, thus, been reported in the literature. The process of the ninth group of embodiments 1.25+0.625x(2.0-TA) as applied to decaffeinated roast and ground coffee by where TA is the Titratable Acidity. enhancing extractability provides a compensatory advantage. 0700. The tenth group of embodiments further relates to a The added flavor and strength advantages achievable by process for preparing these roast and ground or flaked coffee enhanced extractability permits realization of levels of flavor products. This process comprises the steps of: and brew strength which might otherwise not be attainable in 0701 (a) fast roasting green coffee beans comprising from the case of a conventional decaffeinated roast and ground about 50 to 100% high acidity-type coffee beans, from 0 to product. about 30% low acidity-type coffee beans and from 0 to about US 2014/0370181 A1 Dec. 18, 2014 48
50 moderate acidity-type coffee beans that have not been stage roasters (e.g., Probat, Thermalo, Jetzone, etc.) with very predried, or only partially predried, to a Hunter L-color of large heat inputs. These high heat inputs result in the rapid from about 13 to about 19 under conditions that prevent expansion of the roasted bean, but can also cause a high burning and tipping of the beans; degree of bean roasting variation within the roaster. In addi 0702 (b) grinding the roasted coffee beans; tion, tipping and burning of the outer edges of the bean can be 0703 (c) optionally flaking the ground coffee beans. a major problem during fast roasting. 0704. Coffee products of the tenth group of embodiments 0709. One proposed solution for dealing with problems perform across a wide range of brewers delivering a high caused by fast roasting, including tipping and burning, is quality beverage with desirable strength and cup color at a disclosed in U.S. Pat. No. 5,322,703 (Jensen et at), issued Jun. drastically reduced usage. These products are believed to 21, 1994. In the Jensen et al process, green coffee beans are have increased brew absorbance due to the formation (during dried prior to roasting to a moisture content of from about 0.5 fast roasting) and extraction of very large molecules (e.g., to about 7%. These predried beans are then fast roasted to a polysaccharides) from the coffee. What was previously Hunter L-color of from about 10 to about 16. These dried dark unknown was how to make and extract these molecules using roasted coffee beans (about 1 to about 50%) are blended with higher quality coffees and still maintain the desired higher non-dried roasted coffee beans (about 50 to about 99%), and acidity. What has been surprisingly discovered is that by then ground, or ground and flaked. See abstract and column 1, careful fast roasting, even high quality washed Arabicas can lines 50-63. be fast roasted to darker colors without burning. Careful fast 0710. The purpose in predrying according to the Kirk roasting of these higher acidity-type Arabica beans produces patricketal and Jensen etal processes is to make the moisture the desired absorbance compounds, and sufficiently puffs the content of the resultant predried more uniform throughout. beans to allow extraction of these desired compounds. Sub See column 3, lines 52-56 of Kirkpartricket al. While pre sequent mechanical disruption of the beans and cells (grind drying improves the flavor of all coffees, it particularly ing and/or flaking) is also key in extracting these absorbance improves the flavor of lower grade coffees such as the Robus compounds to provide a consumable coffee beverage have the tas. See column 8, lines 45-47. See also column 3, lines 13-15 desired brew strength and cup color. of Jensen et al (dark roasting of non-dried coffee beans, 0705. In connection to the background of the tenth group especially low quality beans such as Robustas can result in of embodiments, historically roast and ground coffee has excessive burnt-rubbery notes.) been marketed on Supermarket shelves by weight in 16-ounce 0711. As alluded to in Jensen et al, a major problem with cans. However, a recent trend in the coffee market has prior high yield coffees is their unbalanced flavor and lack of resulted in the demise of the 16-ounce weight standard. This acidity. See column 1, lines 42-44 (enhancing extractability trend emerged in 1988, when major coffee manufacturers and brew coffee yield can beachieved but often at the expense began marketing 13-ounce blends. The blends were prepared of balanced flavor of the coffee brew). The Jensen et al pro using “fast roast” technology that resulted in a lower density cess tried to improve this balance by blending the dark roasted bean. Thirteen ounces of these lower density blends have pre-dried beans (providing strength with minimal burnt-rub nearly the same volume as the traditional 16-ounce blends. As bery flavor notes) with the lighter roasted non-dried coffees a result they could be marketed in the old 1-pound cans and (to provide flavor and acidity). See column 1, line 64-68. This were priced about 20 cents below the previous 16-ounce list blending does result in higher acidity, but at the expense of price because they used fewer beans. This down-weighting of diluting the high yield benefits of the pre-dried beans. coffee in cans has met with widespread acceptance in the 0712. Historically, coffee brew strength, as well as cup industry. color, has been directly correlated to the level of brew solids 0706. One process using fast roasting to lower bean den present in the brewed cup of coffee. To achieve increased sity is disclosed in U.S. Pat. No. 5,160,757 (Kirkpatricketal), brew strength and cup color, the coffee beans have previously issued Nov. 3, 1992. In the Kirkpatricketal process, the green been roasted faster, darker and with greater concentrations of coffee beans are pre-dried to a moisture content of from about Robustas. Grinding the beans finer and flaking the ground 0.5% to about 10% by weight, fast roasted to a Hunter L-color beans thinner have also been used to increase brew strength of from about 14 to about 25 and a Hunter AL-color of less and cup color. This often leads to undesired tipping and burn than about 1.2, and then ground, or ground and flaked. The ing of the beans, along with harsh, rubbery notes (from the resulting coffee product has a tamped bulk density of from Robustas) in the brewed coffee. Coffee made this way also about 0.28 to about 0.38 g/cc and is more uniformly roasted generally leads to a lack of desired acidity in the brewed compared to traditional reduced density coffee beans. See coffee. abstract and column 2, lines 35-45. 0713. Accordingly, it would be desirable to have a high 0707. Many recent “fast roast coffees also have a higher yield roast and ground or flaked coffee product that provides yield of brew solids than previous 16-ounce coffees. These a coffee beverage having: (1) a darker cup color; (2) increased high yield fast roast and ground coffees exhibit improved brew strength; (3) yet with a desirable level of acidity. extraction characteristics during brewing. Higher yield 0714 One aspect of the tenth group of embodiments pro (sometimes referred to as higher mileage) coffees have typi vides a coffee composition for use in a beverage unit and cally been defined by the ability to extract more brew solids method thereofas defined in the Summary of the Invention, from the coffee beans so that an equivalent brew solids is wherein the coffee composition comprises a roast and ground achieved in the final brew but with less coffee used. In other or flaked coffee product having a Hunter L-color of from words, these higher yield coffees can make more cups of about 13 to about 19 and which comprises from about 50 to coffee per ounce when compared to previous 16-ounce cof 100% high acidity-type coffee, from 0 to about 30% low fees. acidity-type coffee, and from 0 to about 50% moderate acid 0708 Fast roasting results in a puffed or somewhat popped ity-type coffee, said coffee product being capable of provid bean. Fast roasting of coffee typically occurs in large multi ing a consumable coffee beverage having: US 2014/0370181 A1 Dec. 18, 2014 49
0715 (1) a brew solids level of from about 0.4 to about coffee product in a Bunn OL-35 automatic drip coffee maker 0.6%; with a water feed of 1860 ml at 195° F (90° C.). 0716 (2) a Titratable Acidity of at least about 1.52: 0725. As used herein, the term “1-pound coffee can' 0717 (3) a brew absorbance of at least about 1.25, pro relates to a coffee container which has a volume of 1000 cc. vided that when the Titratable Acidity is in the range of from Historically, one pound (16 oz.) of coffee was sold in this about 1.52 to about 2.0, said brew absorbance value is equal Volume container. to or greater than the value defined by the equation: 0726 All particle screens referred to in the tenth group of embodiments are based on the U.S. Standard Sieve Screen 1.25+0.625x(2.0-TA) Series or on the average particle size in microns (um) as wherein TA is the Titratable Acidity. measured by Laser Diffraction on a Sympatec Rodos Helos 0718. In more specific examples under this aspect, the laser particle size analyzer. coffee product comprises from about 70 to 100% high acid 0727. As used herein, the term “comprising means that ity-type coffee, from 0 to about 20% low acidity-type coffee, the various coffees, other ingredients, or steps, can be con and from 0 to about 30% moderate acidity-type coffee, and jointly employed in practicing the tenth group of embodi optionally from about 90 to 100% high acidity-type coffee, ments. Accordingly, the term "comprising encompasses the from 0 to about 10% low acidity-type coffee, and from 0 to more restrictive terms “consisting essentially of and “con about 10% moderate acidity-type coffee. For example, the sisting of coffee product has a Hunter L-color of from about 14 to about 0728. All ratios and percentages in the tenth group of 18 such as from about 15 to about 17. The coffee product may embodiments are based on weight unless otherwise specified. provide a coffee beverage having Titratable Acidity of from about 1.6 to about 3.0; at least about 1.58; and or from about B. Types and Grades of Coffee in the Tenth Group of 1.8 to about 2.7. Embodiments 0719. In more specific examples under this aspect, the 0729) Coffee beans useful in the tenth group of embodi coffee product comprises from about 70 to 100% high acid ments can be either of a single type or grade of bean or can be ity-type coffee, from 0 to about 20% low acidity-type coffee, formed from blends of various bean types or grades, and can and from 0 to about 30% moderate acidity-type coffee, and be caffeinated or decaffeinated. In order to provide the provides a coffee beverage having a brew absorbance from desired acidity in the coffee beverage, the coffee beans useful about 1.3 to about 1.9. in the tenth group of embodiments are predominantly high 0720. In more specific examples under this aspect, the acidity-type beans in mounts of from about 50 to 100%, coffee product comprises from about 70 to 100% high acid preferably from about 70 to 100% and most preferably from ity-type coffee, from 0 to about 20% low acidity-type coffee, about 90 to 100%. As used herein, “high acidity-type beans' and from 0 to about 30% moderate acidity-type coffee, and are defined as beans that deliver greater than about 1.9 Titrat provides a coffee beverage wherein when the Titratable Acid able Acidity. These high acidity-type beans are typically ity is in the range of from about 1.58 to about 2.2, said brew referred to as high grade coffees. Suitable high grade coffee absorbance is equal to or greater than the value defined by the having high acidity include Arabicas and Colombians char equation: acterized as having “excellent body.” “acid.” “fragrant,” “aro matic' and occasionally "chocolatey.” Examples of typical 1.25+0.625x(2.2-TA). high quality coffees are “Milds often referred to as high 0721. In more specific examples under this aspect, the grade Arabicas, and include among others Colombians, coffee product comprises from about 70 to 100% high acid Mexicans, and other washed Milds such as strictly hard bean ity-type coffee, from 0 to about 20% low acidity-type coffee, Costa Rica, Kenyas A and B, and strictly hard bean Guate and from 0 to about 30% moderate acidity-type coffee, and malans. provides a coffee beverage having a brew solids level of from 0730 Coffees useful in the tenth group of embodiments about 0.42 to about 0.58%. can also include from 0 to about 50%, preferably from 0 to 0722. In more specific examples under this aspect, the about 30% and most preferably from 0 to about 10% moder coffee product comprises from about 70 to 100% high acid ate acidity-type coffee beans. As used herein, "moderate acid ity-type coffee, from 0 to about 20% low acidity-type coffee, ity-type beans' are defined as beans that deliver between and from 0 to about 30% moderate acidity-type coffee, and about 1.7 and 1.9 titratable acidity as defined in the Analytical the brew absorbance is equal to or greater than the value Methods section. These moderate acidity-type beans are typi defined by the equation: cally referred to as intermediate grade coffees. Suitable inter mediate quality coffees are the Brazilian coffees such as 2.475- 0.075x(Hunter L-color of coffee). Santos and Paranas, African Naturals, and Brazils free from 0723. The tenth group of embodiments as described above the strong Rioy flavor Such as good quality Suldeminas. Inter will be further described in the following paragraphs and mediate coffees are characterized as having bland, neutral exemplified in Examples 35-44 flavor and aroma, lacking in aromatic and high notes, and are generally thought to be Sweet and non-offensive. A. Definitions in the Tenth Group of Embodiments 0731 Coffees useful in the tenth group of embodiments can also include from 0 to about 30%, preferably from 0 to 0724. The term “density’ means bulk density. Density or about 20% and most preferable from 0 to about 10% low bulk density values herein can be measured by conventional acidity-type coffee beans. As used herein, “low acidity-type means as tamped bulk density values. “Brew solids’ refer to beans' are defined as beans that deliver less than about 1.7 brew solids in a coffee brew obtained understandard brewing titratable acidity as defined in the Analytical Methods section. conditions (as described hereafter in the Analytical Methods These low acidity-type beans are typically referred to as low section) using one ounce of a roasted and ground or flaked grade coffees. Suitable low grade coffees having low acidity US 2014/0370181 A1 Dec. 18, 2014 50 include Robustas, or low acidity natural Arabicas. These low 0737. In the process of the tenth group of embodiments, grade coffees are generally described as having rubbery flavor the green coffee beans are fast roasted in from about 10 notes and produce brews with strong distinctive natural flavor seconds to about 5.5 minutes, preferably in from about 1 to characteristics often noted as bitter. about 3 minutes, using air or another fluidizing heat exchange medium having a temperature of from about 350°F. (177°C.) C. Roasting Coffee Beans in the Tenth Group of to about 1200° F (64.9°C.), preferably a temperature of from Embodiments about 400° F (240° C.) to about 800° F (427°C.). The green 0732 Prior to roasting, the coffee beans can be partially coffees are fast roasted to an average color of from about 13 predried to a moisture content of from about 3 to about 7%. to about 19 Hunter “Hunter units, preferably from about 14 preferably from about 5 to about 7%. Partial predrying can be to about 18 Hunter"L'units, and most preferably from about desirable where a higher proportion of moderate to low acid 15 to about 17 Hunter “L” units. The Hunter Color “L” scale ity-type coffees are used make the moisture more uniform and system is generally used to define the color of the coffee beans thus less Susceptible to tipping and burning. Partial predrying and the degree to which they have been roasted. Hunter Color can be carried out according to any of the methods disclosed 'L' scale values are units of light reflectance measurement, in U.S. Pat. No. 5,160,757 (Kirkpatricket al), issued Nov. 3, and the higher the value is, the lighter the color is since a 1992 or U.S. Pat. No. 5,322,703 (Jensen etal), issued Jun. 21, lighter colored material reflects more light. Thus, in measur 1994, both of which are incorporated by reference to provide ing degrees of roast, the lower the “L” scale value the greater the indicated moisture content values. Preferably, the coffee the degree of roast, since the greater the degree of roast, the beans are not predried prior to roasting and typically have darker is the color of the roasted bean. This roast color is moisture contents in the range of from about 8 to 14%. usually measured on the roasted, quenched and cooled coffee 0733. The coffee beans are carefully roasted under condi beans prior to Subsequent processing (e.g., grinding and/or tions that avoid tipping and burning of the beans. As used flaking) into a finished coffee product. herein, the terms “tipping and “burning relate to the chart 0738. As soon as the desired roast bean color is reached, ing of the ends and outer edges of a bean during roasting. the beans are removed from the heated gases and promptly Tipping and burning of beans results in a burnt flavor in the cooled, typically by ambient air and/or a water spray. Cooling resulting brewed beverage. Tipping and burning can be of the beans stops the roast-related pyrolysis reactions. Water avoided by the combination of using high quality beans with spray cooling, also known as “quenching is the preferred minimal defects, roasting similar sizes and types together, cooling method in the tenth group of embodiments. The uniform heat transfer (preferably convective), and controlling amount of water sprayed is carefully regulated so that most of the heat input rate through the roast to prevent the edges of the the water evaporates off. The roasted and quenched beans are beans from burning. further cooled with air. 0734. In order to achieve the desired darker roast color 0739. After cooling, the roast coffee beans of the tenth without tipping or burning, the coffee beans are fast roasted in group of embodiments have a whole roast tamped bulk den the process of the tenth group of embodiments. Fast roasters sity of from about 0.27 to about 0.38 g/cc, preferably from suitable for use in the tenth group of embodiments can utilize about 0.29 to about 0.36 g/cc, more preferably from about any method of heat transfer. However, convective heat trans 0.30 to about 0.36 g/cc, and most preferably from about 0.30 fer is preferred, with forced convection being most preferred. to about 0.35 g/cc. The convective media can be an inert gas or, preferably, air. Typically, the pre-driedbeans are charged to a bubblingbedor fluidized bed roaster where a hot air stream is contacted with D. Grinding Roasted Beans in the Tenth Group of the bean. Suitable roasters capable of forming a fluidized bed Embodiments of green coffee beans include the JetZone(R) roaster manufac ture by Wolverine (U.S.), the Probat(R) roaster manufactured 0740 The roasted coffee beans can then be ground using by Probat-Werke (Germany), the Probat RT or RZ. roaster any conventional coffee grinder. Depending upon the specific manufactured by Probat-Werke (Germany), the Burns Sys particle size distribution desired in the final product of the tem 90 roaster by Burns (Buffalo, N.Y.), the HYC roaster by tenth group of embodiments, the coffee fractions can be Scolari Engineering (Italy), and the Neotec RFB by Neotec ground to the particle size distributions or “grind sizes' tra (Germany). Any other roasting equipment which causes a ditionally referred to as “regular,” “drip, or “fine' grinds. For rapid heating of the bean Such as that achieved through flu example, automatic drip coffee grinds typically have an aver idization can be used. age particle size of about 900 um and percolator grinds are 0735 Roasting equipment and methods suitable for roast typically from about 1500 um to about 2200 um. The stan ing coffee beans according to the tenth group of embodiments dards of these grinds as suggested in the 1948 Simplified are described, for example, in Sivetz, Coffee Technology, Avi Practice Recommendation by the U.S. Department of Com Publishing Company, Westport, Conn. 1979, pp. 226-246, merce (see Coffee Brewing Workshop Manual, page 33, pub incorporated herein by reference. See also U.S. Pat. No. lished by the Coffee Brewing Center of the Pan American 3.964,175 (Sivetz) issued Jun. 22, 1976, which discloses a Bureau) are as follows: method for fluidized bed roasting of coffee beans. 0736. Other fast roasting methods useful intenth group of Grind Sieve (Tyler) Wt.% embodiments are described in U.S. Pat. No. 5,160,757 (Kirk Regular on 14-mesh 33 patricket al), issued Nov. 3, 1992; U.S. Pat. No. 4,737,376 on 28-mesh 55 (Brandlein et al.), issued Apr. 12, 1988: U.S. Pat. No. 4,169, through 38-mesh 12 164 (Hubbard et al.), issued Sep. 25, 1979; and U.S. Pat. No. Drip on 28-mesh 73 4.322,447 (Hubbard), issued Mar. 30, 1982, all of which are through 28-mesh 27 incorporated by reference. US 2014/0370181 A1 Dec. 18, 2014 51
-continued dark cup of coffee is the first thing that a coffee drinker typically looks for. The coffee drinker will initially look at the Grind Sieve (Tyler) Wt. 90 cup of coffee to visually judge its strength. If the cup is too Fine through 14-mesh 1OO clear and allows light to transmit through it, it is usually on 28-mesh 70 considered too weak. However, if the brew in the cup is too through 28-mesh 30 dark so that virtually no light can transmit through it, it is usually considered too strong. 0747. Before ever tasting the coffee, the coffee drinker has 0741. Typical grinding equipment and methods for grind thus judged in their mind as to what the strength will be, and ing roasted coffee beans are described, for example, in Sivetz by tasting it, confirms through taste what they have already & Foote, “Coffee Processing Technology.” Avi Publishing visually seen. Therefore, an adequately strong cup of coffee Company, Westport, Conn., 1963, Vol. 1, pp. 239-250. must first visually look dark. Second, with the lower usage's E. Flaking Roast and Ground Coffee in the Tenth Group of of high yield, high mileage coffees, the consumer is con Embodiments stantly skeptical of the coffee being weak. Therefore, espe cially for high mileage coffees, the brew must be dark to 0742 Coffee products according to the tenth group of prevent it from being judged weak. embodiments can be flaked. 0748 Traditionally, the darker the cup of coffee, the stron 0743 Preferred flaked products are produced by grinding ger it is. This observation is true of high mileage coffees. the roast coffee to an average particle size from about 300 to Except for the formation of offensive flavors (burnt, robbery, about 3000 um, normalizing the ground product, and then rioy), the darkness of the cup almost always correlates with milling the coffee to a flake thickness of from about 2 to about the strength. Therefore, by measuring and controlling the cup 40 thousandths of an inch (about 51 to about 1016 um), darkness, one can not only predict the visual response to cup preferably from about 5 to about 30 (about 127 to about 762 darkness, but can also somewhat predict its true strength um), most preferably from about 5 to about 20 (about 127 to (assume no offensive flavors). about 508 um). Suitable methods and apparatus for flaking 0749. To technically measure the darkness of the coffee are disclosed in, for example, U.S. Pat. No. 3,615,667 (Joffe), brew, a spectrophotometer is used to measure the amount of issued Oct. 26, 1971; U.S. Pat. No. 3,660,106 (McSwiggin et light absorbance by the liquidbrewed coffee. A wavelength of al), issued May 2, 1972; U.S. Pat. No. 3,769,031 (McSwig 480 nanometers was chosen because it corresponds with the gin), issued Oct. 30, 1973: U.S. Pat. No. 4,110,485 (Grubbs et Brown Color absorbance on the visible spectrum. (Brown al), issued Aug. 29, 1978; and U.S. Pat. No. 5,064,676 (Gore), color is typically associated with stronger coffee brews.) This issued Nov. 12, 1991, all of which are incorporated by absorbance at 480 nm correlates with the visually perceived reference. darkness in the cup. 0750 Coffee beverages prepared from roast and ground or F. Characteristics of Beverage Obtained by Brewing Roast flaked coffee products according to the tenth group of and Ground or Flaked Coffee Product in the Tenth Group of embodiments have a brew absorbance of at least about 1.25, Embodiments with a typical range of from about 1.3 to about 1.9. However, when the coffee beverage has a Titratable Acidity (TA) in the 1. Brew and Titratable Acidity range of from about 1.52 to about 2.0, this brew absorbance is 0744. An important characteristic of coffee beverages pre equal to or greater than the value defined by the equation: pared from roast and ground or flaked coffee products accord ing to the tenth group of embodiments is brew acidity. A high 1.25+0.625x(2.0-TA) quality coffee brew is typically noted for its acidity. Coffee (0751. Preferably, when the coffee beverage has a TA in the brews having high acidity are typically obtained from high range of from about 1.58 to about 2.2, this brew absorbance is quality beans. The problem previously with high yield, high equal to or greater than the value defined by the equation: mileage coffees is the use of less coffee (dilution), darker roasting (which tends to decrease acidity) and the use of 1.25+0.625x(2.2-TA) stronger flavored Robustas (which generally have less acid ity). Therefore, higher acidity becomes vital in maintaining a 3. Brew Solids in the Tenth Group of Embodiments high quality brew for high mileage coffees. 0752 Another important characteristic of coffee bever 0745. The ability of coffee to buffer pH changes in the ages prepared from roast and ground or flaked coffee products mouth is its main indicator of acidity perception. This buff according to the tenth group of embodiments is the level of ering capability can be measured by titrating the brew to pH brew solids. Brew solids are simply the solids remaining after 7 with sodium hydroxide and is thus referred to as Titratable oven drying the brewed coffee. Brew solids is an indication of Acidity (TA). Coffee beverages prepared from roast and the mass transfer that has occurred from the Solid grounds to ground or flaked coffee products according to the tenth group the water phase during brewing. While the level of brew solids of embodiments have a TA of at least about 1.52, with a is a good indicator of the efficiency of the extraction and typical range of from about 1.6 to about 3.0. Preferably, these completeness, it does not discriminate as to what compounds coffee products have a TA of at least about 1.58, with a typical are extracted. Indeed, green coffee has a considerable fraction range of from about 1.8 to about 2.7. of extractable brew solids, even though the subsequent brew prepared from this green coffee lacks coffee flavor. 2. Cup Color and Brew Absorbance 0753 High yield, high mileage coffees have concentrated 0746. Another important characteristic of coffee bever on extracting more of the available brew solids. This has been ages prepared from roast and ground or flaked coffee products beneficial in providing good extraction of the majority of the according to the tenth group of embodiments is cup color. A compounds that are low molecular weight (i.e., simple Sug US 2014/0370181 A1 Dec. 18, 2014 52 ars). However, until the tenth group of embodiments, very 0765 b. Operation little attention has been paid to studying how to make and 0766 Weigh 200 g of whole bean coffee to be tested into extract more of the strength compounds. beaker. Place the graduated cylinder on the vibrator. Using the 0754. It is believed that the compounds that contribute to funnel, pour the coffee sample into the cylinder. Level the the additional strength and cup darkness of coffee beverages coffee by gently tapping the side of the cylinder. Vibrate 30 prepared from roast and ground or flaked coffee products seconds at No. 8 setting. Read volume to nearest 5 ml. according to the tenth group of embodiments is due to very Tamped density can be determined by dividing the weight of high molecular weight molecules such as polysaccharides. the coffee by the volume occupied (after vibrating) in the These compounds may not be at very high levels, but are very graduated cylinder. functional because of their size, geometry and full chemical 0767 For standardizing the measurements between differ structure. The low level of these very functional molecules ent coffees, all density measurements herein are on a 4.5% can be almost insignificant when compared to the total brew adjusted moisture basis. For example, 200 grams of whole Solids. bean coffee having a 2% moisture content would contain 196 0755. Although the level of brew solids is an incomplete g of dry coffee and 4 g of water. If the volume was 600 cc, the measurement of brew strength, it is still a good indicator of unadjusted density would be 200 g/600 cc-0.33 g/cc. On a overall extraction efficiency. Accordingly, coffee products 4.5% adjusted moisture basis, the calculation is: 4.5%x200 according to the tenth group of embodiments maintain a high gms=9 gms water. To make the density calculation on an extraction efficiency, as measured by brew solids. For coffee adjusted moisture basis, take 196 g dry coffee--9 g water-205 beverages prepared from roast and ground or flaked coffee gtotal. Adjusted density=205 g/600 cc-0.34 g/cc. products according to the tenth group of embodiments, the level of brew solids is in the range of from about 0.4 to about 0.6%. Preferably, coffee beverages prepared from coffee 2. Roasted Coffee Color products according to the tenth group of embodiments have a 0768. The Hunter Color “L” scale system is generally used level of brew solids in the range of from about 0.42 to about to define the color of the coffee beans and the degree to which O.58%. they have been roasted. A complete technical description of the system can be found in an article by R. S. Hunter “Pho 4. Relationship of Brew Absorbance to Roast Color of Coffee toelectric Color Difference Meter.” J. of the Optical Soc. of 0756. Another important characteristic of roast and Amer. 48,985-95 (1958). In general, it is noted that Hunter ground or flaked coffee products according to the tenth group Color “L” scale values are units of light reflectance measure of embodiments is the relationship of brew absorbance to ment, and the higher the value is, the lighter the color is since roast color. There is a natural tendency as the coffee is roasted a lighter colored material reflects more light. In particular, in darker for it to produce more of the strength and color com the Hunter Color system the “L” scale contains 100 equal pounds. Coffee products according to the tenth group of units of division; absolute black is at the bottom of the scale embodiments provide coffee beverages having an increased (L=0) and absolute white is at the top (L=100). Thus, in brew absorbance at a given degree of roast color. This can be measuring degrees of roast, the lower the “L” scale value the quantified by the relationship of the brew absorbance of the greater the degree of roast, since the greater the degree of coffee beverage produced from the coffee product relative the roast, the darker is the color of the roasted bean. roast color of the coffee product. Coffee products according to the tenth group of embodiments preferably have a brew 3. Brewing absorbance equal to or greater than the value defined by the equation: 0769 Coffee is brewed on a Bunn OL-35 automated drip brewer. Coffee filters are 12 cup oxygen processed Bunn 2.475- 0.075x(Hunter L-color of coffee) Coffee filters (Reg. 6001). One ounce of coffee is added to the filter in the basket. The brewer is supplied with distilled water G. Analytical Methods in the Tenth Group of Embodiments and feeds 1860 ml at 195° F (90° C.) in 146 seconds to the brew basket. Brewed coffee is collected in a carafe and then 1. Whole Roast Tamped Bulk Density Determination mixed. Samples for brew solids, brew absorbance, and Titrat able Acidity are then collected. 0757. This method determines the degree of puffing that occurs in the roasting of green coffee and is applicable to both 4. Brew Absorbance decaffeinated and non-decaffeinated whole roasts. (0758 a. Apparatus (0770. The brewed coffee is placed in a 12 ml sealed vial 0759 Weighing container: 1,000 ml stainless steel beaker and then cooled for 10 minutes in a water bath at 29°C. The or equivalent sample is then transferred to a cuvette and the absorbance is 0760 Measuring container: 1,000 ml plastic graduated measured in a Milton Roy Spectrophotometer 401 at 480 nm cylinder, 5 ml graduations wavelength. 0761 Scale: 0.1 gm sensitivity 0762. Vibrator: Syntron Vibrating Jogger; Model J-1 or 5. Brew Solids equivalent. Syntron Company—Homer City, Pa. (0771. The brewed coffee is placed in a 12 ml sealed vial 0763 Funnel: Plastic funnel with tip cut off to about 1" and allowed to cool. The sample is then analyzed for solids outlet content by index of refraction using a Bellingham & Stanley 0764) Automatic Timer: Electric, Dimco-Gray; Model RFM 81, where the sample temperature during the measure No. 171 or equivalent ment is maintained at 29°C. The readings are correlated with US 2014/0370181 A1 Dec. 18, 2014
readings of reference Solutions of known brew Solids content through a No. 30 screen. The moisture content of the flakes is based on oven drying techniques using a correlation of between 2.5% and 9.0% by weight, preferably between 3.5% and 7.0%. Refractive Index=0.001785x(% brew solids)+1. 331995. (0778 U.S. Pat. No. 4,267,200 to Klien et al., issued May 12, 1981, discloses coffee flake particles that are aggregates of low moisture flakes (1% to 3.5% moisture by weight) and 6. Titratable Acidity high moisture flakes (4.5% to 7% moisture by weight). The (0772. From a mixed carafe, 100 g of a coffee brew is flake thickness is between 0.009 and 0.016 inch (0.23–0.41 collected, covered with a lid, and allowed to cool. The coffee mm). Preferred flaked coffee compositions have a particle brew is then titrated to 7 pH using 0.1N sodium hydroxide size such that 0-12% remains on a No. 12 U.S. Standard solution, recording the milliliters required as the Titratable Screen, 2-28% passes through a No. 12 but remains on a No. Acidity (ml 0.1N NaOH). 16 screen, 10-30% passes through a No. 16 but remains on a No. 20 screen, 10-25% passes through a No. 20 but remains 7. Green Coffee Acidity on a No. 30 screen, and 30-60% passes through a No. 30 SCC. 0773) To assess the acidity level in green coffee, the coffee 0779 U.S. Pat. No. 3,625,704 to Andre et al., issued Dec. is roasted in a standard way, to a standard condition, ground 7, 1971, discloses instant coffee flakes with improved aroma and flaked, brewed and then the Titratable Acidity measured: and flowability having a thickness preferably between 0.002 A 100 pound charge of coffee is fed to a Thermalo roaster, Model Number 23R, manufactured by Jabez Burns and a gas and 0.010 inch (0.05-0.25 mm), and a moisture content before burner input rate of about 1.4 million BTU/hr. such that the flaking of between 0.5% and 7.0%. The flakes have a size coffee is roasted to color of 17 Hunter Linapproximately 210 ranging between 0.02 and 0.10 inch (0.5-2.5 mm). seconds. The coffee is then quenched to 4.5% moisture and 0780 U.S. Pat. No. 3,660,106 to McSwiggin et al., issued cooled. After grinding and Subsequent flaking to a 14 mil May 2, 1972, discloses roast and ground coffee flakes having thickness, the product is brewed (per method 3 above) and the a thickness of 0.008-0.025 inch (0.20-0.63 mm) and a mois Titratable Acidity is measured (per method 6 above method). ture content before flaking of 2.5-7.0% by weight. The par 0774. In preparing the coffee compositions as defined in ticle size of the coffee after flaking is not disclosed. The flakes the Summary of the Invention, the coffee in the coffee com are said to be produced in high yield, and to have good position 110/130 and beverage material 120 as shown in structural integrity and little or no flavor degradation. FIGS. 1A, 1B, and 1C may have various cell structures. As (0781 U.S. Pat. No. 4,110,485 to Grubbs et al., issued Aug. previously mentioned, flaked roast and ground coffee is con 29, 1978, discloses high sheen roast and ground coffee flakes templated in the present invention. The eleventh group of having a flake thickness of 0.008-0.025 inch (0.20-0.63 mm). embodiments according to the present invention provides a Particle size of the flakes is not disclosed. The moisture level flaked coffee with improved brewing properties. More par before flaking is about 5-6%. ticularly, the eleventh group of embodiments relates to flaked 0782 U.S. Pat. No. 3,769,031 to McSwiggin, issued Oct. coffee with increased extractability and decreased brewing 30, 1973, discloses roast and ground coffee flakes having a time. thickness between 0.012 inch and 0.027 inch (0.3-0.7 mm), 0775. The eleventh group of embodiments is related to a and a moisture content before flaking between 2.5% and roast and ground flaked coffee that provides the benefits of 7.0%. Particle size of the flakes is not disclosed. increased extractability and decreased brewing time. The cof 0783 U.S. Pat. No. 2,281,320 to Odell, issued Apr. 28, fee flakes may have a thickness of from about 0.004 inch to 1942, discloses roast and ground coffee flakes having a thick about 0.018 inch (about 0.10 mm to about 0.46 mm), a mois ness between 0.001 and 0.020 inch (0.025-0.51 mm), prefer ture level of from about 3% by weight to about 6% by weight, ably between 0.007 and 0.010 inch (0.18-0.25 mm), and a and a particle size fines level such that from about 30% to moisture content between 25% and 45% before flaking. The about 50% by weight of the particles pass through a No. 20 patent does not discuss particle size after flaking U.S. Pat. No. U.S. Standard Screen. The flake thickness, moisture level, 3,640,727 to Heusinkveld, issued Feb. 8, 1972, discloses and fines level are related by a brew solids equation. flaked coffee having a flake thickness preferably between 0776. In connection to the background of the eleventh 0.005 and 0.025 inch (0.13-0.64 mm), and a moisture content group of embodiments, numerous prior patents disclose vari before flaking between 2% and 8%. Particle size after flaking ous kinds of flaked roast and ground coffee. For example, is not discussed. U.S. Pat. No. 3,615,667 to Joffe, issued Oct. 26, 1971, dis 0784. Although some of the patents state that their flakes closes thick-flaked roast and ground coffee characterized by have improved extractability, the patents do not suggest how improved flavor and aroma. The flake thickness is 0.008-0. to make a flaked coffee that provides maximum extractability 025 inch (0.20-0.63 mm), preferably 0.010-0.016 inch (0.25 when it is brewed in the 72-gallon coffee brewers and urn 0.41 mm), and the flake moisture level is 2.5-7.0% by weight, brewers typically used in the foodservice industry. Moreover, preferably 3.0-6.0%. The flakes have a particle size such that the prior patents do not describe how to control the interaction 3-10% pass through a No. 40 U.S. Standard Screen and not between flake thickness, moisture level, and fine particle size more than 35% remain on a No. 12 screen. level to achieve this increased extractability. (0777 U.S. Pat. No. 4.331,696 to Bruce, issued May 25, 0785. One aspect of the eleventh group of embodiments 1982, discloses extra-thin flaked roast and ground coffee with provides for a coffee composition for use in a beverage unit structural integrity. The flake thickness ranges from 0.004 to and method thereofas defined in the Summary of the Inven 0.008 inch (0.10-0.20 mm). The flaked coffee has no more tion, wherein the coffee composition comprises non-decaf than 90% by weight particles passing through a No. 30 U.S. feinated roast and ground coffee flakes, wherein the flakes Standard Screen, and preferably 40-70% particles passing have: US 2014/0370181 A1 Dec. 18, 2014 54
0786 (a) an average thickness of from about 0.004 inch to decaffeinated roast and ground coffee flakes particularly about 0.022 inch; suited for use in a /2-gallon brewer, wherein the flakes have: 0787 (b) an average moisture level of from about 3% to 0802 (a) an average thickness of from about 0.004 inch to about 6% by weight; and about 0.018 inch; 0788 (c) a particle size fines level such that from about 0803 (b) an average moisture level of from about 3% to 30% to about 50% by weight of the particles pass through a about 6% by weight; and No. 20 U.S. Standard Screen, and from about 20% to about 0804 (c) a particle size fines level such that form about 50% by weight of the particles pass through a No. 40 U.S. 30% to about 50% by weight of the particles pass through a Standard Screen; and No. 20 U.S. Standard Screen, and from about 20% to about 0789 (d) wherein the average flake thickness (“FT'), 50% by weight of the particles pass through a No. 40 U.S. average moisture level (“MO”), and particle size fines level (“FF) are adjusted according to the following equation: Standard Screen; and (0805 (d) wherein the average flake thickness (“FT'), 0.36 to 0.96=0.686+(0.0244xFT)–(0.0150xFF)+(0. average moisture level (“MO”), and particle size fines level 00217xMOxFF). (“FF) are adjusted according to the following equation: 0790 For example, the average flake thickness, average 0.57 to 0.90=1.254-(0.0361xMO)-(0.0221xFT)-(0. moisture level, and particle size fines level may be adjusted 00504xFF)+(0.00068xMOxFF). according to the following equation: 0806 For example, the average flake thickness, average 0.79 to 0.89=0.686+(0.0244xFT)–(0.0150xFF)+(0. moisture level, and particle size fines level may be adjusted 00217xMOxFF). according to the following equation: 0791) Another aspect of the eleventh group of embodi 0.79 to 0.89=0.686+(0.0244xFT)–(0.0150xFF)+(0. ments provides for a coffee composition for use in a beverage 00217xMOxFF). unit and method thereof as defined in the Summary of the Invention, wherein the coffee composition comprises decaf 0807 Still another aspect of the eleventh group of embodi feinated roast and ground coffee flakes particularly suited for ments provides for a coffee composition for use in a beverage use in an urn brewer, wherein the flakes have: unit and method thereof as defined in the Summary of the 0792 (a) an average thickness of from about 0.004 inch to Invention, wherein the coffee composition comprises decaf about 0.022 inch; feinated roast and ground coffee flakes particularly suited for 0793 (b) an average moisture level of from about 3% to use in a /2-gallon brewer, wherein the flakes have: about 6% by weight; and 0808 (a) an average thickness of from about 0.004 inch to 0794 (c) a particle size fines level such that from about about 0.018 inch; 30% to about 50% by weight of the particles pass through a 0809 (b) an average moisture level of from about 3% to No. 20 U.S. Standard Screen, and from about 20% to about about 6% by weight; and 50% by weight of the particles pass through a No. 40 U.S. 0810 (c) a particle size fines level such that from about Standard Screen; and 30% to about 50% by weight of the particles pass through a 0795 (d) wherein the average flake thickness (“FT'), No. 20 U.S. Standard Screen, and from about 20% to about average moisture level (“MO”), and particle size fines level 50% by weight of the particles pass through a No. 40 U.S. (“FF) are adjusted according to the following equation: Standard Screen; and 0.30 to 0.90=0.686+(0.0244xFT)–(0.0150xFF)+(0. 0811 (d) wherein the average flake thickness (“FT'), 00217xMOxFF). average moisture level (“MO”), and particle size fines level 0796 For example, the average flake thickness, average (“FF) are adjusted according to the following equation: moisture level, and particle size fines level may be adjusted 0.51 to 0.84=1.254-(0.0361xMO)-(0.0221xFT)-(0. according to the following equation: 00504xFF)+(0.00068xMOxFF). 0.73 to 0.83=0.686+(0.0244xFT)–(0.0150xFF)+(0. 0812 For example, the average flake thickness, average 00217xMOxFF). moisture level, and particle size fines level may be adjusted 0797. In more specific examples under the above two according to the following equation: aspects, the flakes may have an average thickness of from 0.73 to 0.83=0.686+(0.0244xFT)–(0.0150xFF)+(0. about 0.014 inch to about 0.022 inch. 00217xMOxFF). 0798. In more specific examples under the above two aspects, the flakes may have an average moisture level of from 0813. In more specific examples under the above two about 4.5% to about 5.5% by weight. aspects, the flakes may have an average moisture level of from 0799. In more specific examples under the above two about 0.004 inch to about 0.014 inch. aspects, the flakes may have a particle size fines level Such 0814. In more specific examples under the above two that from about 35% to about 45% by weight of the particles aspects, the flakes may have an average moisture level of from pass through a No. 20 U.S. Standard Screen. about 4.5% to about 5.5% by weight. 0800. In more specific examples under the above two 0815. In more specific examples under the above two aspects, the flakes may have been fast roasted for a time aspects, the flakes may have a particle size fines level Such between about 1 minute and about 1.5 minutes at a tempera that from about 35% to about 45% by weight of the particles ture between about 590°F. and about 605 F. pass through a No. 20 U.S. Standard Screen. 0801 Still another aspect of the eleventh group of embodi 0816. In more specific examples under the above two ments provides for a coffee composition for use in a beverage aspects, the flakes may have been fast roasted for a time unit and method thereof as defined in the Summary of the between about 1 minute and about 1.5 minutes at a tempera Invention, wherein the coffee composition comprises non ture between about 590°F. and about 605 F. US 2014/0370181 A1 Dec. 18, 2014
0817. The eleventh group of embodiments as described 0826 Coffee flakes particularly suited for use in a /2- above will be further described in the following paragraphs gallon brewer have an average thickness between about 0.004 and exemplified in Examples 45-46. inch (0.10 mm) and about 0.018 inch (0.46 mm), preferably 0818. It was discovered that there were drawbacks associ between about 0.004 inch (0.10 mm) and about 0.014 inch ated with the flaked coffee previously sold to customers in the (0.36 mm). foodservice industry. A weak-tasting brewed coffee was pro duced because the coffee flakes did not provide optimum 2. Moisture Level extractability in foodservice industry brewing machines. The brewing time was longer than desired. There were occasional 0827. The coffee flakes of the eleventh group of embodi incidences of cup sediment resulting from filter overflow. ments have an average moisture level of about 3% to about 0819. In view of these problems with the previous coffee, 6% by weight of the coffee flakes. Preferred coffee flakes work was conducted in which flaked coffee samples were have an average moisture level of about 4.5% to about 5.5% made having varying moisture levels, flake thicknesses, and by weight. particle size fines levels (defined here as percent particles 0828 Typically, moisture level of the flaked coffee is through a No. 20 U.S. Standard Screen). The samples were adjusted by varying the moisture level of the roast and ground brewed in two brewing machines commonly used in the food coffee feed from which the flakes are produced. The adjust service industry: a Bunn OL-20/2-gallon brewer and a Cecil ments to the feed moisture level can be controlled, for ware FE-100 urn brewer. Data on brew solids, brew time, and example, by controlling the amount of water used to quench extraction efficiency were collected. and thereby halt the roasting operation. If a cool air quench is 0820. It is believed that different moisture levels, flake used, the moisture level can be adjusted by spraying on addi thicknesses, and particle sizes, and different relationships tional water after quenching or after grinding. The moisture between these parameters, are needed to provide optimum level of the roasted beans is not appreciably affected by the extractability of flaked coffee brewed in different kinds of grinding or milling operations. brewing machines (i.e., foodservice industry brewers versus other brewers, and /2-gallon brewers versus urn brewers). 3. Particle Size Distribution 0821 Specifically, for a /2-gallon brewer used in the food service industry it is believed that flake thickness, the inter 0829. The coffee flakes of the eleventh group of embodi action between moisture level and fines level, and the inter ments have a particle size which is adjusted so that the level of action between flake thickness and fines level are important to fine particles is within a specified range, where “fine par maximizing brew Solids yield. Optimum brewing perfor ticles' is defined herein as the percentage of particles that pass mance occurs as moisture level increased, flake thickness through a No. 20 U.S. Standard Screen. The coffee flakes decreases, and particle size fines level decrease. have a particle size fines level such that from about 30% to 0822. For a foodservice industry urn brewer it is believed about 50% by weight of the particles pass through a No. 20 that moisture level, flake thickness, finished product fines U.S. Standard Screen. Preferably from about 35% to about level, and the interaction effect between moisture level and 45% by weight of the particles pass through a No. 20 U.S. fines level are important to maximizing brew Solids yield. Standard Screen. Optimum brewing performance occurs as moisture level 0830. It is conventional in the coffee art to describe coffee increases, flake thickness increases, and particle size fines particle size distribution, including flaked coffee, in terms of level decrease. These interactions are described by different screen or "sieve” fractions, i.e. that weight percentage which equations which have been calculated for the /2-gallon remains on a particular screen or that weight percentage brewer and the urn brewer, and which are disclosed below in which passes through a particular screen. For example, a Section 4. flaked coffee product might have a screen analysis Such that 0823 Roast and ground coffee flakes made according to 40% by weight passes through a U.S. Standard No. 20 Screen the eleventh group of embodiments by carefully controlling with 60% by weight remaining on the No. 20 screen. Since the the moisture level, flake thickness, product fines level, and screen opening for a No. 20 U.S. Standard Screen is approxi interactions between these parameters, have increased mately 0.033 inch (0.84 mm), such a coffee product would extractability so that a desirably stronger coffee beverage can comprise about 40% by weight of particles which have a be made. The coffee flakes brew more rapidly, so a shorter particle width less than 0.033 inch, while the remaining brewing time is required. When the coffee flakes are used in weight fraction would comprise particles which have a par the form of loose ground coffee in paper filters, there are ticle size greater than the 0.033 inch size opening. fewer incidences of cup sediment resulting from filter over flow. 0831. The present coffee flakes have a particle size that is larger than the extra-thin flakes described in U.S. Pat. No. 0824 Flake thickness, moisture level, particle size distri 4.331,696 to Bruce, and smaller than the thick flakes bution, and the relationship between these characteristics for described in U.S. Pat. No. 3,615,667 to Joffe. Whereas the the present coffee flakes are discussed herein below: flakes disclosed by Joffe have a particle size such that 3-10% 1. Flake Thickness pass through a No. 40 U.S. Standard Screen, the flakes of the eleventh group of embodiments have a size such that between 0825. The roast and ground coffee flakes of the eleventh about 20% and about 50% pass through a No. 40 screen. The group of embodiments particularly Suited for use in an urn most preferred flakes disclosed by Bruce have a particle size brewer have an average flake thickness between about 0.004 such that about 50% passes through a No. 30 U.S. Standard inch (0.10 mm) and about 0.022 inch (0.56 mm), preferably Screen, while the flakes of the eleventh group of embodi between about 0.014 inch (0.36 mm) and about 0.022 inch ments have a size such that between about 20% and about (0.56 mm). The method for measuring average flake thick 60% pass through a No. 30 screen. Further, the Bruce flakes ness is described hereinbelow in Section 6. will have too many particles that pass through a No. 20 screen. US 2014/0370181 A1 Dec. 18, 2014 56
4. Brew Solids Equations cups of equal brew strength and flavor to be brewed from a given amount of coffee. The normal method of measuring the 0832. The following equations describe the interactions strength of a coffee brew is to measure the percent soluble between flake thickness, moisture level and particle size fines solids, which is commonly referred to as “brew solids'. The level necessary to produce maximum brew solids when brew method for measuring brew solids is described in Section 6 ing in an urn brewer or a /2-gallon brewer: hereinbelow. a) Urn Brewer 0842. The percent brew solids measurement is dependent on the weight of coffee and the volume of water used in the 0833 For caffeinated (regular) coffee flakes particularly brewing process. For example, at column 12, lines 29-62 of suited for use in an urn brewer, the desired brew solids yield U.S. Pat. No. 4,331,696 to Bruce, 57.0 grams of coffee are is between about 0.36% and about 0.96%, preferably between brewed in a Bunn OL2012-cup (/2-gallon) brewing machine, about 0.79% and about 0.89%. This brew solids yield is on the and the percent brew solids is 0.88%. On the other hand, the basis of brewing 283.5 grams of the flaked coffee in an urn percent brew Solids range in the eleventh group of embodi brewer with 3 gallons of water. Key variables are adjusted ments is on the basis of brewing 48.2 grams of coffee with /2 according to the following equation to provide a target yield gallon of water. The Bruce example would have about 0.74% of from about 0.36% to about 0.96% brew solids during brew solids on the basis of using 48.2 grams of coffee brewing: (0.88%x48.2/57.0), whereas in the eleventh group of embodi 0.36 to 0.96=0.686+(0.0244xFT)–(0.0150xFF)+(0. ments up to about 0.90% brew solids can be obtained using a 00217xMOxFF). /2-gallon brewer. 0834 “FT represents the average flake thickness in mils 0843 “Urn brewers” and “/2-gallon brewers” are the two (thousandths of an inch). (If 'FT' is given in millimeters, the types of brewers commonly used in the foodservice industry, FT part of the equation changes to “(0.959xFT)”.)“FF rep and these terms are known to those skilled in the art. resents the particle size fines level, which is defined as the Examples ofurn brewers area Cecilware FE-100 urn brewer, percentage of flakes which pass through a No. 20 U.S. Stan a Bunn urn brewer, and a Blickman urn brewer. Examples of dard Screen. “MO' represents the average moisture level in /2-gallon brewers are a Bunn OL-20 /2-gallon brewer, a weight percent. Cecilware /2-gallon brewer, and a Curtis /2-gallon brewer. 0835. The actual measured brew solids yield may be 0844) Urn brewers are described in Sivetz et al., Coffee slightly different from the brew solids yield calculated from Technology, Avi Publishing Co. (1979), at pages 635, 636, the equation. However, the important thing is that the mois 673-675 and 676-680. Essentially, urn brewers are large ture level, flake thickness and fines level be chosen to fit into heated pots that hold a large Volume of coffee (e.g., between the equation to provide the target brew Solids range; if they are 3 and 12 gallons or more). The coffee is generally prepared by so chosen, that will provide the optimum actual brew solids. pumping or spraying near boiling water through ground or As discussed above, preferably the actual measured brew flaked coffee held in a filter at the top of the urn. Half gallon Solids is within the target calculated range. brewers can have various designs and operating modes (most 0836. As an illustration, if a flaked coffee product has a common is a drip coffee maker), but what they all have in flake thickness of 0.008 inch (8 mils), a fines level of 54%, and common is that they hold /2 gallon of coffee. Sivetz et al., a moisture level of 5.9%, the percent calculated brew solids is supra, at pages 673-675, discusses coffee brewing in the 0.76% as follows: foodservice industry. Urns and /2-gallon brewers are dis 0.686+(0.0244x8)-(0.0150x54)+(0.00217x5.9x54) cussed at the bottom of page 674. In Table 17.1 at page 675, =0.76 it is disclosed that /2-gallon brewers comprise about 70% of 0837 Since about 0.06% soluble solids in a regular non the brewing equipment used in restaurants, while urns com decaffeinated coffee brew consist of caffeine, coffee which prise about 23%. has been decaffeinated will contain fewer brew solids. For decaffeninated coffee the desired brew solids range is 0.30% 5. Preparation of the Flaked Coffee to 0.90%, preferably 0.73% to 0.83%. b) /2-Gallon Brewer a) Starting Material Selection 0838 For non-decaffeinated (regular) coffee flakes par ticularly suited for use in a /2-gallon brewer, the desired brew 0845 The roast and ground flaked coffee of the eleventh solids yield is between about 0.57% and about 0.90%, pref. group of embodiments can be made from a variety of roast erably between about 0.79% and about 0.89%, when 48.2 and ground coffee blends, including those which may be grams of the flaked coffee is brewed with /2 gallon of water. classified for convenience and simplification as low-grade, The following equation is used for these flakes: intermediate-grade, and high-grade coffees. Suitable 0.57 to 0.90=1.254-(0.0361xMO)-(0.0221xFT)–(0. examples of low-grade coffees include the natural Robustas 00504xFF)+(0.00068xMOxFF). Such as the Ivory Coast Robustas and Angola Robustas, and the Natural Arabicas such as the natural Penis and natural 0839) (If “FT is given in millimeters instead of mils, the Ecuadors. Suitable intermediate-grade coffees include the FT part of the equation changes to "(0.871 xFT)”.) natural Arabicas from Brazil Such as Santos, Paranas and 0840 For decaffeinated coffee the desired brew solids Minas, and natural Arabicas Such as Ethiopians. Examples of range is 0.51% to 0.84%, preferably 0.73% to 0.83%. high-grade coffees include the washed Arabicas Such as Mexicans, Costa Ricans, Colombians, Kenyas and New c) Definitions Guineas. Other examples and blends thereofare known in the 0841. The greater extractability provided by the flaked art. Decaffeinated roast and ground coffee also can be used coffee of the eleventh group of embodiments enables more herein to make a decaffeinated flaked coffee product. US 2014/0370181 A1 Dec. 18, 2014 57 b) Roasting 0856 To produce the present coffee flakes, the roll pres 0846 Green coffee beans are roasted to a Hunter'L' color sure should be within the range of from about 37.5 lbs./linear of from about 18 to about 23. It is preferable that the beans are inch of nip to about 300 lbs./linear inch of nip, preferably subjected to a “fast roasting process whereby they are from about 56 lbs./linear inch to about 94 lbs./linear inch. The roasted for approximately 1 to approximately 5 minutes, roll surface temperature should be between 50° F. and 80° F., more preferably for about 1 to about 1.5 minutes, attempera preferably between 60° F. and 80° F. The diameter of the roll tures between about 590° F (310°C.) and about 605° F (318° mills should be between about 6 inches and about 48 inches, C.). Ifbeans are roasted for less than 1 minute, the roast is not preferably between about 6inches and about 30 inches. Pref uniform and insufficient flavor development occurs. Fast erably a Zero static gap is used, but suitable gap settings range roasting is preferred because higher aroma levels and extract from 0 up to about 0.001 inch. The moisture content of the able Solids are generated. roast and ground coffee feed is between about 3% and about 0847. After the coffee beans have been roasted they are 6%. The feed rate is between about 50 lbs./hr, finch and about cooled to a temperature below about 65° F (18°C.) by con 160 lbs./hr./inch; preferably starve feeding is used. The roll ventional water quenching, followed by additional cooling peripheral surface speed of the roll mill is from about 328 using refrigerated air to achieve the desired temperature. ft./minute to about 1,414 ft/minute, preferably from about Instead of water quenching, other cooling methods such as 707 ft/minute to about 1,178 ft/minute. liquid nitrogen, carbon dioxide, cool air, etc., can also be 0857. After the roast and ground coffee feed has been used. flaked by being passed through the roll mill, it is preferred but not essential that the flaked coffee be screened to remove any c) Grinding oversized flakes caused by the presence of impurities in the 0848. The flaked coffee of the eleventh group of embodi roast and ground coffee feed. It is also possible to remove ments can be ground to “coarse”, “regular”, “drip’ or “fine” excessive fine particles caused by a secondary grinder effect. sizes known to the art. Preferably the coffee is ground to a If screening is conducted, it is preferred to use a Sweco 'coarse' grind. As used herein, "coarse' grind size indicates screening device equipped with a 12 mesh U.S. Standard that the roast and ground coffee has a particle size distribution Screen, and to screen the coffee between about 120 seconds such that: and 240 seconds. 0849 (a) from 40% to 95% by weight retained on a No. 12 U.S. Standard Screen, 6. Measurement Techniques 0850 (b) from 0% to 37% by weight retained on a No. 16 U.S. Standard Screen, a) Flake Thickness 0851 (c) from 0% to 12% by weight retained on a No. 20 U.S. Standard Screen, 0858 100 grams of the flaked coffee is poured onto a 0852 (d) from 0% to 10% by weight retained on a No. 30 circular U.S. Standard No. 12 Screen and is agitated by a U.S. Standard Screen, “Ro-Tap' sieve (screen) shaker (manufactured by U.S. Tyler 0853 (e) from 0% to 8% by weight pass through a No. 30 Co.) for three minutes. The flaked coffee which passes U.S. Standard Screen. through the No. 12 screen is thereafter similarly screened for 0854 Typical grinding equipment and methods for grind three minutes using a U.S. Standard Screen No. 16. Ten ing roasted coffee beans are described, for example, in Sivetz representative flakes from the portion remaining on the No. & Foote, "Coffee Processing Technology' 1963, Vol. 1, pp. 16 screen are selected for flake thickness measurement. Each 239-250. representative flake particle is measured for thickness using a Federal Model 22P-10 gauge manufactured by Federal Co. d) Roll Milling The ten flake thickness measurements are averaged to char 0855. The roll milling operation to make the flaked coffee acterize the average flake thickness. of the eleventh group of embodiments is similar to that described at column 7, line 8, to column 9, line 56, of the U.S. b) Moisture Level Pat. No. 4331,696 to Bruce, issued May 25, 1982, which disclosure is herein incorporated by reference. However, the 0859. The average moisture level of the flakes is measured present coffee flakes are not as thin as the extra-thin flaked using a standard moisture meter, specifically a Computrac coffee described by Bruce, and the present flakes are larger in Moisture Analyzer, Model MA-5A, manufactured by Quintel particle size than the Bruce flakes. Accordingly, compared to Corporation. the Bruce patent, the roll milling conditions will be adjusted Somewhat to produce slightly larger and thicker flakes. The c) Particle Size Distribution means of producing these flakes is not critical as long as the resultant flakes have the required product characteristics. 0860. The particle size distribution of the coffee flakes is Larger, thicker flakes can be made by adjusting any of several measured by the use of a “Ro-Tap' multiple sieve shaker processing parameters, such as decreasing the roll pressure, manufactured by U.S. Tyler Co. The following circular U.S. increasing the static gap between the rolls, or decreasing the Standard Screens are mounted on the sieve shaker: No. 12, roll peripheral surface speed at the same feed rate. These No. 16, No. 20, No. 30, and optionally No. 40 (and a pan to interactions are described generally at column 10, line 39 to collect the particles passing through all the screens). 100 column 13, line 37 of U.S. Pat. No. 4,267,200 to Klien et al., grams of the coffee flakes are poured onto the No. 12 screen, which disclosure is incorporated by reference herein, and and the sieve shaker is agitated for 3 minutes. Then the weight specifically at column 12, lines 52-64 and column 13, lines percentage of particles on each screen and in the pan are 26-37. measured. US 2014/0370181 A1 Dec. 18, 2014
d) Brew Solids disclosed in U.S. Pat. No. 4,110,485, issued Aug. 29, 1978 to 0861. The percent “brew solids” or soluble solids in the D. R. Grubbs. A flaked coffee product with large visually coffee brew can be measured by oven-drying the brewed distinctive flakes can be prepared by flaking a mixture of two coffee and weighing the remaining solids. The percent brew roast and ground coffee blends of equal weight fractions. The Solids can also be ascertained optically by measuring the two coffee blends differ only in their moisture content; one index of refraction of the coffee brew. The index of refraction being a high moisture (5.0% by weight) coffee, and one being is correlated to brew Solids as measured by the oven-drying a low moisture coffee (3% by weight). technique. 0866 While flaking can provide roast coffee in a form 0862 In preparing the coffee compositions as defined in the Summary of the Invention, the coffee in the coffee com which provides certain benefits such as increased extractabil position 110/130 and beverage material 120 as shown in ity and can be used to provide visually distinctive coffee FIGS. 1A, 1B, and 1C may have various cell structures. As products, coffee flaking can detrimentally affect certain previously mentioned, flaked roast and ground coffee is con attributes of roast and ground coffee. Flaking is known, for templated in the present invention. The twelfth group of example, to reduce the initial aroma level of packaged coffee embodiments according to the present invention provides as well as to affect the quality of the aroma. To minimize the aggregated mixed-moisture flaked coffee of high aroma. The aroma penalty exacted by flaking, mixtures of conventional twelfth group of embodiments relates to roast and ground roast and ground coffee and of flaked coffee have been for coffee products comprising aggregated coffee flake particles mulated (see, for example, U.S. Pat. No. 3,615,667 issued which comprise a plurality of compressed coffee flakes Oct. 26, 1971 to F. M. Joffe). However, such mixtures merely bonded together. The aggregated flake coffee products pro trade off increased initial aroma for increased extractability vide improved extractability of the water-soluble flavor con when conventional roast and ground coffee which has a stituents, Superior initial aroma levels and acceptable bed higher aroma level is substituted for flaked coffee which has permeabilities. The twelfth group of embodiments also higher extractability. relates to a novel process for preparing the aggregated flake coffee particles by the roll milling of a cold processed coffee 0867. The initial aroma level of flaked coffee could be feed blend of ground coffees having differing moisture con increased by the simple addition of a highly aromatized car tents under particular roll mill operating conditions. rier oil such as is disclosed in U.S. Pat. No. 3,769,032, issued 0863 More particularly, the twelfth group of embodi Oct. 30, 1973 to Lubsen et al. Such an addition, however, ments is related to aggregated coffee flake particles that com would undesirably increase the oil level of the coffee itself as prise a plurality of compressed coffee flakes bonded together well as any coffee brew made therefrom. Moreover, the aroma wherein at least one of which is a low-moisture flake (1% to material from relatively large quantities of donor coffee must 3.5% by weight) and at least one of which is a high-moisture be collected in order to aromatize small quantities of flaked flake (4.5% to 7% by weight) are disclosed. The composite coffee. flake particles range in thickness from 9 to 16 mils. The flaked 0868. A variety of non-donative or unadulterating aroma coffees provide improved extractability of the water-soluble tization methods are known in the art for increasing the aroma flavor constituents, exhibit high initial aroma levels, and of roast and ground coffee. Typically, these methods involve exhibit high bed permeability. Also disclosed is a process for reducing the working temperature of coffee at various stages preparing aggregated mixed-moisture flaked coffee. The pro of processing Such as grinding. The cooler working tempera cess comprises: (1) separately cold-grinding dual streams of tures reduce losses of the Volatile aroma materials during roast coffee, relatively high-moisture and low-moisture, these steps (see, for example, U.S. Pat. No. 1,924,059, issued respectively; (2) combining of the two ground coffee streams Aug. 22, 1933 to W. Hoskins). These cold grinding processes to provide a roll mill feed having a specified particle size for conserving aroma have not been applied to minimizing the distribution and average moisture content, and (3) passing the aroma losses of flaked coffee, apparently, because, as noted coffee feed through a roll mill under specific conditions, and above, flaking is known to reduce the level of coffee aroma. (4) screening the roll-milled, aggregated flaked coffee to pro Thus, any increase in the aroma of roast and ground coffee duce a product such that no more than 60% by weight passes apparently would be lost during flaking. However, it is through a 30-mesh U.S. Standard screen. believed that application of pre-flaking, non-donative aroma 0864. In connection to the background of the twelfth conservation methods such as cold processing can provide an group of embodiments, roast and ground coffee which has increase in the initial aroma level of flaked coffee. been transformed into flaked coffee by roll milling the roast and ground coffee is known in the art (see, for example, U.S. 0869. Such a combination of aroma conservation and flak Pat. No. 1,903,362, issued Apr. 4, 1933 to R. B. McKinnis, ing methods is, however, not made without certain difficul and U.S. Pat. No. 2,368,113, issued Jan. 30, 1945 to C. W. ties. An unforeseen disadvantage associated with flaked cof Carter). An improved flaked roast and ground coffee of fee which has been cold processed is a dramatic decrease in enhanced extractability is disclosed by Joffe in U.S. Pat. No. the bed permeability of a coffee product produced. Such 3,615,667, issued Oct. 26, 1971, as well as a method for its decreases in bed permeability lead to unacceptably long drain production in U.S. Pat. No. 3,660,106, issued May 2, 1972 to times needed to prepare coffee brews. J. R. McSwiggin et al. 0870 Given the state of the coffee flaking art as described 0865 Art attempts are realizing superior roast coffee above, there is continuing need for new and useful roast products have included improving other coffee attributes in coffee products which provide increased extractability of the addition to improving the extractability of those flavorful flavorful coffee brew solids and which possess high initial water-soluble coffee constituents often referred to as coffee aroma levels. Accordingly, it is an object of the twelfth group brew Solids. A visually appealing, high-sheen flaked roastand of embodiments to provide a flaked roast coffee product of ground coffee of improved extractability of its brew solids is increased extractability and enhanced initial aroma. US 2014/0370181 A1 Dec. 18, 2014 59
0871. It is a further object of the twelfth group of embodi 0884. In more specific examples under this aspect, the ments to provide roast coffee products of enhanced extract particle size distribution of said coffee mixture is such that ability and initial aroma which are substantially free of addi 0885 (a) from 0% to about 80% by weight of the roll mill tive aroma carrier oils. coffee feed is retained on a 12 mesh U.S. Standard size screen, 0872. It is a further object of the twelfth group of embodi 0886 (b) from about 0% to 40% by weight of the roll mill ments to provide flaked roast coffee products of enhanced coffee feed (goes through 12 but) is retained on a 16 mesh extractability and initial aroma which have bed permeabilities U.S. Standard screen, and great enough to provide acceptable coffee bed draining per 0887 (c) from about 0% to 45% by weight of the roll mill formance. coffee feed (goes through 16 but) is retained on a 20 mesh 0873. It is believed that the above objects can be realized U.S. Standard size screen, and superior flaked roast coffee products provided which 0888 (d) from 0% to 55% by weight of the roll mill coffee exhibit both enhanced extractability and initial aroma levels feed (goes through 20 but) is retained on a 30-mesh U.S. as well as adequate bed permeability by formulating aggre Standard size screen, and gated, mixed-moisture flaked coffee compositions. Such cof 0889 (e) from 0% to 40% by weight of the roll mill coffee fee compositions are realized by mixing a low-moisture roast feed goes through a 30 mesh U.S. Standard size screen. and ground coffee fraction and a high-moisture coffee frac 0890 For example, the low-moisture coffee beans may tion, each of which has been cold processed to minimize have a moisture content of from about 1.5% to 2.5% by coffee aroma losses, and thereafter flaking the roast and weight of said low-moisture coffee and wherein the high ground coffee mixed-moisture blend under particular roll moisture coffee has a moisture content of from about 5.5% to mill conditions. The novel, mixed-moisture coffee flake 6.5% by weight of the high-moisture coffee. The coffee mix aggregates produced Surprisingly possess Sufficient structural ture of step (C) may have an average moisture content of 3.5% strength and integrity to provide bed permeability equivalent to 4.5%. The comminuting of the roasted low-moisture coffee to non-cold processed flaked coffee. beans and the comminuting of the roasted high-moisture cof 0874. One aspect of the twelfth group of embodiments fee beans may be each at a temperature of between 20 F. and provides a coffee composition for use in a beverage unit and 35°F. The roll mill may be operated at a zero static gap. In that method thereofas defined in the Summary of the Invention, case, the roll mill may have wherein the coffee composition comprises an improved (0891 I. a roll pressure of from about 1,000 lbs./linear inch flaked roast coffee product characterized by increased of nip to 2,000 lbs./linear inch of nip, extractability of the water-soluble flavor constituents and (0892 II, a roll temperature of about 60° F. to 70° F., and increased initial aroma intensity and comprising coffee flake (0893 III. a roll peripheral speed of from about 1180 ft./ aggregates, made from a method comprising the steps of min. to 1650 ft/min. 0875 (A) comminuting roasted low-moisture coffee 0894 For example, the low-moisture coffee beans and the beans at a temperature of below 40° F., said low-moisture high-moisture coffee beans may be each separately commi coffee beans having a moisture content of from about 1% to nuted along with frozen carbon dioxide in a weight ratio of about 3.5% by weight of said low-moisture coffee beans beans to carbon dioxide of about 6:1, said carbon dioxide thereby forming a low-moisture roast and ground coffee; having a particle size of less than about 0.25 inch in diameter. For Such a process, the low-moisture coffee beans may have 0876 (B) comminuting roasted high-moisture coffee a moisture content of 2% by weight of said beans and wherein beans at a temperature of below 40° F., said high-moisture the high-moisture coffee beans may have a moisture content coffee beans having a moisture content of about 4.5% to 7% of 6% by weight. by weight of said high-moisture coffee, thereby forming a 0895. The twelfth group of embodiments as described high-moisture roast and ground coffee; above will be further described in the following paragraphs, 0877 (C) admixing said low-moisture roast and ground illustrated in FIGS. 8-9, and exemplified in Examples 47-49. coffee and said high-moisture roast and ground coffee at a 0896. The twelfth group of embodiments relates to temperature of below 40° F., the mixture having an average unadulterated, highly aromatic flaked coffee compositions moisture content of about 3% to 5% by weight; (D) passing which nonetheless exhibit normal drain time performance the coffee mixture of step (C) through a roll mill at a feed rate characteristics and to the process by which Such compositions of about 10 lbs./hr.-inch of nip to 400 lbs./hr.-inch of nip, said are prepared. The present roast coffee compositions comprise roll mill having from about 80% to 100% by weight of coffee flake aggre 0878 (I) a roll pressure of from about 150 lbs./in. of nip to gates. The coffee flaked aggregates comprise a plurality of about 4000 lbs./in. of nip, compressed coffee flakes bonded together. At least one of the 0879 (II) a roll temperature of from about 40° F. to about coffee flakes in each aggregate is a low-moisture flake, having 80° F., a moisture content of from about 1% to about 3.5% by weight. Additionally, at least one of said coffee flakes in each aggre 0880 (III) a static gap setting of less than 0.001 inch, gate is a high-moisture flake, having moisture content of from 0881 (IV) a roll peripheral speed of from about 470 ft./ about 4.5% to 7% by weight of the high-moisture flake. The min. to 1880 ft/min., and average moisture content is from about 3% to about 5% by 0882 (V) a roll diameter of from about 6 inches to 48 weight of the coffee composition. inches, to produce coffee flake aggregates having a flake 0897. The balance of the present roast coffee composi thickness of about 0.009 inch to 0.016 inch; and thereafter tions comprises other conventional coffee materials including 0883 (E) screening said coffee flake aggregates to pro conventional flaked coffee, high-sheen flaked coffee, and duce a flaked roast coffee product such that no more than 60% roast and ground coffee or the like, including grains. by weight of said product passes through a U.S. Standard 30 0898. The coffee flake aggregates have an average flake mesh screen. thickness of from about 0.009 to 0.016 in. The bulk density of US 2014/0370181 A1 Dec. 18, 2014 60 the present coffee compositions range from about 0.395 g/cc. roast and ground particles can enter the roll mill in Sufficient to 0.485 g/cc. The initial aroma intensity of the present com proximity to one another such that when flattened by the positions is about 20,000 G.C. total counts or above as mea compressive action of the roll milling operation, the edges of sured by the procedure described herein. compressed coffee can overlap. The compressive force of the 0899. The twelfth group of embodiments also provides a roll mill presses together the overlapping flake platelets and process by which the above-described roast coffee composi forms a particle wherein a plurality of flakes are bonded tions can be prepared. In the present process two separate together. Due to the cohesive nature of the coffee, bonding of green bean fractions are separately roasted and quenched the flake platelets occurs simply as a result of the roll milling with sufficient amounts of water such as to provide individual operation and without the presence of any adulterating bind moisture contents of from about 1% to about 3.5% and from ing agents. 4.5% to 7%, respectively, in conventional manner. Thereafter, 0904 Surprisingly, it is believed that certain flake aggre each whole roast fraction is cooled to -5° F. to 5° F., and is gates have sufficient structural strength Such as to provide separately ground so as to provide a low-moisture roast and acceptable bed permeability even though made from cold ground coffee and a high-moisture roast and ground coffee processed roast and ground coffee. To possess such structural respectively. Each of these fractions is within the temperature strength, it is essential that each flake aggregate comprise at range of 20°F. to 40°F. after grinding. The high-moisture and least one high-moisture coffee flake or “flake platelet' low-moisture coffees are blended while maintaining the tem bonded to at least one low-moisture flake coffee. By “high perature of the coffee below 40° F., preferably within the moisture' flake platelet as used herein, it is meant the coffee range of 30° F. to 40° F. to form a mixed-moisture roll mill flake platelet which is prepared from a roast and ground roast and ground coffee feed having an average moisture coffee having a moisture content of from about 4.5% to 7% by content of from about 3% to 5% by weight of the coffee feed. weight. Similarly, a “low-moisture’ flake platelet is prepared The roll mill coffee feed is then fed to a roll mill at a tem from “low moisture' roast and ground coffee having a mois perature of about 35° F to 40° F. and at a feed rate of about 10 ture content of from about 1% to 3.5% by weight. Since each to 400 lbs./hr./in. The roll mill operates at a roll pressure of flake aggregate contains at least one high-moisture and one about 150 to 4000 lbs./linear in...; a roll temperature of from low-moisture flake platelet, the present flake aggregates are about 40° F. to 80° F.; a mechanical static gap of less than referred to herein as “mixed-moisture’ flake aggregates. 0.001 in...; a roll peripheral speed of from about 470 to 1180 (0905 Referring now to the FIGS. 8 and 9, particularly to ft/min...; and a roll diameter of from about 6 to 48 inches. The FIG.9, there is shown a perspective view of one embodiment aggregated, mixed-moisture flaked coffee falling from of the present mixed-moisture flaked aggregates. The flake between the rolls is thereafter screened to adjust the final aggregate 1 is comprised of a plurality of flake platelets 2, 3, particle size distribution. 4, 5 and 6 of any shape bonded together. Each flake aggregate 0900. The twelfth group of embodiments relates to flaked contains at least one low-moisture flake platelet 2. Each flake roast coffee compositions comprising particles of aggregated aggregate also contains at least one high-moisture flake plate mixed-moisture flakes of roast coffee. The present coffee lets 3, 4, 5 and 6. products exhibit increased extractability of the water-soluble 0906. Of course, the present coffee flake aggregates can contents, Superior levels of aroma, and acceptable bed per contain more than one high- or one low-moisture flake plate meability so as to allow the expeditious provision of a flavor let. Indeed, the larger coffee flake aggregates (e.g., flakes ful coffee brew. The processes by which the present flaked retained on a U.S. Standard 12 mesh screen) comprise a large coffees are prepared are also disclosed herein. number of each of low-moisture and high-moisture coffee flakes. Referring to FIG.9, there is shown a perspective view Aggregated Mixed-Moisture Flaked Coffee of a second embodiment of the mixed-moisture flaked aggre 0901. In the provision of an aggregated mixed-moisture gates. The flake 1 is comprised of a plurality of flake platelets flaked coffee product having enhanced extractability, 2',3', 4' 5", 6", 7" and 8. Such a flake aggregate contains a enhanced aroma, and acceptable bed permeability, it is impor plurality of low-moisture flake platelets 2', 5', and 7". Also, tant to control the structure of the aggregated flaked particles, each Such flake aggregate contains a plurality of high-mois the flake thickness, flake moisture content, particle size dis ture flake platelets 3', 4', 6', and 8. tribution, bulk density, and aroma intensity. Each of these 0907 Superior aggregated mixed-moisture coffee flakes coffee product properties, as well as product preparation and are realized when the low-moisture flakes or flake platelets product use, are described in detail as follows: have a moisture content of from about 1.5% to 2.5% and the high moisture of flakes or flake platelets have a moisture A. Structure content of from about 5.5% to 6.5%. Suitable results are achieved when the low-moisture flakes have a moisture con 0902. The mixed-moisture flaked coffee of the twelfth tent of 2% by weight and the high-moisture flake content is group of embodiments comprises particles which are coffee 6% by weight. flake aggregates. Such flake aggregates comprise a plurality of compressed coffee flakes bonded together. The terms “cof fee flakes' or “flaked coffee' as used interchangeably herein B. Flake Thickness refer to compressed roast and ground coffee particles which (0908. The improved flaked coffee products provided have length to thickness ratios exceeding about 2:1 and gen herein comprise coffee flake aggregates having a flake thick erally less than about 8:1. Such coffee flakes can be produced ness ranging from about 9 mils to 16 mils (i.e., 0.009 inch to by roll milling roast and ground coffee. 0.016 inch). A superior coffee product has an average flake 0903. When certain processing conditions are employed thickness within the range of from 10 to 14 mils. Suitable (as described in detail below) in the roll milling step, coffee results are achieved when the flake thickness is about 12 mils. flake aggregates are prepared. During roll milling, individual Such coffee flake aggregates provide improved extractability US 2014/0370181 A1 Dec. 18, 2014
of the flavorful, water-soluble coffee constituents compared low moisture flakes within the above-specified ranges for to thicker flaked coffee products disclosed by the prior art or these flake components as well as the respective weight frac commercially sold. tions of the low- and high-moisture flakes. (0909. The greater extractability provided by the novel 0915. The component flake or flake platelet moisture con aggregated mixed-moisture flaked coffee product provided tents are adjusted by varying the moisture levels of the whole herein enables more cups of equal-brew strength and flavor to roast beans and thereby the roast and ground coffee feeds be brewed from a given amount of coffee. In comparison to an from which the flakes are produced. The adjustments to the equal weight of conventionally processed coffee, it is feed moisture level can be controlled, for example, by con believed that the increase in titratable acidity for the aggre trolling the amount of water used to quench and thereby to gated flaked coffee product described herein is proportion halt the exothermic roasting operation, and, thereafter, allow ately less than the increase in extractability. Therefore, not ing the coffee beans to come to moisture equilibrium prior to only could more cups of equal-brew strength be brewed from grinding. Neither the grinding nor the flaking operations a given amount of thin-flaked coffee, but the equal-brew appreciably affect the moisture content of the coffee. strength cups would also have lower acidity, which is often described by a consumeras less bitter. D. Particle Size Distribution 0910. The normal method of measuring the strength of a 0916. As noted above, the aggregated flaked coffee pro coffee brew is to measure the percent soluble solids, com vided herein has a flake thickness within a select, particular monly referred to as brew solids. This measurement can be thickness range. It is also important to control the dimension made by oven-drying the brewed coffee and weighing the which characterizes the particle size of the coffee flakes in remainder. The percent soluble solids can also be ascertained order to control bed draining performance. optically by measuring the index of refraction of the coffee (0917. It is conventional in the coffee art to describe coffee brew. The index of refraction is correlated to brew solids as particle size distribution including flaked coffee—in terms measured by the oven-drying technique. of sieve fractions, i.e., that weight percentage which remains 0911 Production of thinner flake aggregates requires, on a particular sieve or that weight percentage which passes generally, more severe compression during the roll milling through a particular sieve. For example, a hypothetical coffee operation. The more severe compression adversely affects the product might have a sieve analysis Such that 40% by weight aroma levels of flaked coffee. Thus, even for the more highly remains on a U.S. Standard No. 14 sieve with 60% by weight aromatic, cold-processed coffee of the twelfth group of passing through a No. 14 sieve. Since the sieve opening for a embodiments, thicker flaked coffee (e.g., 15 mils in thick No. 14 sieve is approximately 55 mils, such a coffee product ness) will have an initial aroma level higher than thinner would comprise about 40% by weight of particles which have flaked coffee (e.g., 10 mils in thickness). However, thinner a particle size greater than 55 mils, while the remaining flaked coffee generally provides greater brew solids per unit weight fraction would comprise particles which have a par weight. Particular balances of extractability and aroma level ticle size less than the 55 mil-size opening. are thus a matter of choice. 0918 Many coffee users have their standards based on using “Tyler standard screen scale testing sieves. The only C. Moisture Content difference between U.S. Standard sieves and the Tyler screen 0912. The aggregated flake coffee products disclosed scale sieves is the identification method. Tyler screen scale herein have an average moisture content of from about 3% to sieves are identified by the nominal meshes per liner inch 5% by weight of the coffee product. Preferred coffee products while the U.S. Standardsieves are identified by millimeters or have an average moisture content of from about 3.5% to 4.5% microns or by an arbitrary number which does not necessarily by weight. For best results, the average moisture content of mean mesh count. the present coffee products should be 4.2%. Of course, the 0919 Generally, an acceptable aggregated flaked coffee average moisture content of the present coffee compositions product can be made whose sieve analysis corresponds to is to be distinguished from the moisture content of individual those particle size distributions commonly referred to as flake platelets of which the present aggregated flake particles “regular”, “drip” and “fine” (defined below). Preferred flaked are comprised. coffee compositions have a particle size distribution Such 0913 Low average moisture contents are to be avoided that: because, in general, the aggregated flakes are fragile. The fragile agglomerated flakes can break during process han dling, packaging and shipping. Too large a percentage of Sieve (U.S. Standard) Wt. 90 broken flakes in turn changes the bulk density. If the density Remains on No. 12 O-12 falls outside the range of from 0.395 g/cc to 0.485 g/cc, the Through No. 12 but remains on No. 16 2-28 product is unacceptable to the consumer. Moreover, even the Through No. 16 but remains on No. 20 1O-30 present aggregated flake particles will exhibit poor bed per Through No. 20 but remains on No. 30 10-2S meability/drain time performance if the average moisture Passes through No. 30 30-60 content is too low. On the other hand, excessively high mois ture contents are to be avoided because the flakes can become 0920 Maintenance of the particle size distribution of the tacky and oily in appearance. Additionally, high average present aggregated coffee products within the above given moisture contents promote water extrusion during milling ranges provides both improved extractability as well as which can cause a substantial increase in the Staling propen acceptable bed draining performance. sity of the resultant coffee product. 0914 Typically, the average moisture content of the E. Bulk Density present aggregated flake coffee products is controlled by 0921. The aggregated flaked coffee product of the twelfth varying the moisture levels of the high moisture flakes and the group of embodiments should have a bulk density of from US 2014/0370181 A1 Dec. 18, 2014 62 about 0.395 g.fcc. to 0.485 g.fcc. in order to assure its con cas Such as Ethiopians. Examples of high-grade coffees Sumer acceptability. Bulk densities within this range are include the washed Arabicas such as Mexicans, Costa Ricans, desirable since conventionally prepared roast and ground cof Colombians, Kenyas and New Guineas. Other examples and fees of “regular”, “drip', and “finegrinds have bulk densities blends thereof are known in the art and illustrated in, for within this range. Fortunately, the twelfth group of embodi example, U.S. Pat. No. 3,615,667 (issued Oct. 26, 1971 to ments provides flakes of high structural integrity. The desir Joffe), herein incorporated by reference. ability of flakes of high structural integrity (i.e., physical 0927 Decaffeinated roast and ground coffee can also be strength and resistance to attrition or breakage during pack used herein to make a decaffeinated thin-flaked coffee prod aging) is important because large percentages of broken uct. As is known in theart, the removal of caffeine from coffee flakes occasioned by transportation can markedly change the products frequency is accomplished at the expense of the bulk density as well as present an unappealing appearance, removal of certain other desirable components which contrib produce settlement after packaging, and cause cup sediment ute to flavor. The tendency of decaffeinated products to be in the brew. either weak or deficient in flavor has, thus, been reported in the literature. The provision of thin-flaked coffee made from F. Initial Aroma Concentration decaffeinated roast and ground coffee by the novel thin-flak 0922. The present flaked coffee product has an initial ing method of the twelfth group of embodiments provides a aroma concentration as measured by the method described compensatory advantage. The added flavor and strength below of at least about 20,000 GC total counts. Better flaked advantages achievable by enhanced extractability permits coffee products of the twelfth group of embodiments have at realization of levels of flavor and brew strength which might least about 25,000 GC total counts. For best results, the otherwise not be attainable in the case of a conventional present fixed coffee products should have an initial aroma decaffeinated roast and ground product. concentration of at least about 30,000 GC total counts. 0928 Typically, decaffeination of coffee is accomplished 0923. As used herein, “aroma’ refers to those aromatic by solvent extraction prior to the roasting of green coffee volatile materials which are present in the headspace or void beans. Such decaffeination methods are well known in the art space in contained or packaged coffee. Thus, 'aroma'as used and illustrated in, for example, U.S. Pat. No. 3,671,263 (is herein is to be distinguished from the coffee aroma resulting sued Jun. 20, 1972 to Patel); U.S. Pat. No. 3,700.464 (issued from brewing, and from the coffee aroma detectable above a Oct. 24, 1972 to Patel); U.S. Pat. No. 3,700,465 (issued Oct. freshly prepared coffee brew. The term “initial aroma' is 24, 1972 to Lawrence); and U.S. Pat. No. 3,671,262 (issued intended to refer to the aroma level of the present flaked Jun. 20, 1972 to Wolfson). See also “Coffee Processing Tech coffee products at equilibrium in a sealed container prior to nology', by Sivetz & Foote. The Avi Publishing Co., West opening. It is, of course, realized that any coffee product if port, Conn., 1963, Vol. II, pp. 207 to 278. Each of these allowed to remain exposed to open air will eventually lose its references are herein incorporated by reference. aroma due to the volatile and fugitive nature of coffee aroma materials. Preparation of Aggregated Flaked Coffee 0924. High initial aroma concentrations of coffee aroma, 0929. The aggregated, mixed-moisture flaked coffee of of course, provide the desirable “fresh coffee' aroma impres the twelfth group of embodiments can be formed by mixing sion to the coffee user upon opening the coffee container. together a low-moisture stream and a high-moisture stream of Further, the high initial aroma concentrations of the twelfth conventional roast and ground coffee, each of which has been group of embodiments have some beneficial effect upon the cold processed, and then Subjecting the coffee to the com organoleptic properties of coffee brews made from the pressive pressures of a roll mill operating underparticular roll present coffee products. milling conditions. Thereafter, the aggregated flaked coffee 0925. The high initial aroma concentrations of the present so produced is sized by Suitable means to achieve the requisite development are achieved by minimizing the aroma losses of particle size distribution of the present aggregated flake cof the roast coffee in the grinding, mixing and flaking steps of fee compositions. the present process of preparation. While it is hypothetically possible to achieve similar initial aroma levels by the addition A. Cold Grinding of a highly aromatized oleaginous carrier oil, the addition of 0930 Two coffee bean fractions are independently ground Such adulterating Substances is not contemplated herein. The in the process of the twelfth group of embodiments. A first addition of such materials would undesirably increase the oil coffee fraction is a low-moisture fraction and comprises cof level in the present coffee products above the natural oil level fee beans having a moisture content of from about 1% to 3.5% of the coffee. by weight of the low-moisture beans. The second bean frac tion is a high-moisture fraction and comprises coffee beans G. Starting Material Selection having a moisture content of from about 4.5% to 7.0% by 0926 The aggregated, mixed-moisture flaked coffee pro weight of the high-moisture beans. Each coffee fraction is vided herein can be made from a variety of roast and ground ground separately but in a similar manner. coffee blends, including those which may be classified for 0931. It is important in the process of preparing the present convenience and simplification as low-grade, intermediate flaked coffee product that each coffee fraction be cold ground. grade, and high-grade coffees. Suitable examples of low By “cold grinding or “cold comminuting herein, it is meant grade coffees include the natural Robustas such as the Ivory that the ground coffee exit the coffee grinder at a ground Coast Robustas and Angola Robustas; and the Natural Ara coffee temperature below 40°F. preferably from about 20°F. bicas such as the natural Penis and natural Ecuadors. Suitable to 40°F. intermediate-grade coffees include the natural Arabicas from 0932. A variety of cold grinding methods are known and Brazil such as Santos, Paranas and Minas; and natural Arabi may be used herein. Two common “cold grinding processes US 2014/0370181 A1 Dec. 18, 2014
are (1) cooling the whole roast coffee to a temperature of -5° tained at a temperature of 35 F. to 40° F. Best results are F. to 5° F. before grinding, and (2) mixing the whole roast obtained when the coffee fractions temperature is between coffee with Solid carbon dioxide, dry ice, just prior to grind about 35 F. and 40° F. during blending. This cold blending 1ng. minimizes aroma material losses and thus aids the realization 0933. The grinding of the coffee beans mixed with solid of the initial aroma levels exhibited by the aggregated flaked carbon dioxide or the like is described in detail in U.S. Pat. coffee products of the twelfth group of embodiments. No. 1,924,059 (issued Aug. 22, 1933 to W. Hoskins). The dry ice, for example, is mixed with coffee beans in a weight ratio C. Roll Milling of coffee to dry ice of about 6 to 9 lbs. to 1 lb. The dry ice should have a particle size of less than about /4 in. diameter. 0939. In the step of roll milling the mixed moisture roast Thereafter, the dry ice/coffee bean mixture is comminuted in and ground coffee to produce the present aggregated flaked a conventional manner to form a roast and ground coffee. coffee, it has been found important to control several process However, any cold grinding method can be utilized which ing variables: (1) coffee feed temperature, (2) roll surface maintains the coffee during grinding at a temperature below temperature, (3) roll diameters, (4) static gap, (5) the roastand 40° F., preferably below 35° F. ground coffee feed moisture content, (6) feed rate, (7) roll 0934 Depending upon the specific particle size distribu peripheral surface speed, (8) roll pressure, (9) the mill feed tion desired in the final product of the twelfth group of particle size distribution, and (10) density of mill feed. embodiments, the coffee fractions can be ground to the par 0940. The process of the twelfth group of embodiments ticle size distributions or “grind sizes' traditionally referred can be practiced with the aid of any of a variety of roll mills of to as “regular”, “drip', or “fine' grinds. The standards of these various roll diameters capable of subjecting roast and ground grinds as suggested in the 1948 Simplified Practice Recom coffee to mechanical compressing action and adapted to the mendation by the U.S. Department of Commerce (see Coffee adjustment of roll pressure, roll speed and roll temperature. Brewing Workshop Manual, page 33, published by the Coffee Suitable mills are those having two parallel rolls such that Brewing Center of the Pan American Bureau) are as follows: coffee particles passed between the rolls are crushed or flat tened into flakes. Normally, smooth or highly polished rolls will be employed as they permit ready cleaning; other rolls Sieve (Tyler) Wt. 90 can, however, be employed if the desired flaking effects can “Regular grind': on 14-mesh 33% be obtained. on 28-mesh 55% through 38-mesh 12% 1. Coffee Feed Temperature “Drip grind': on 28-mesh 7396 through 28-mesh 27% “Fine grind': through 14-mesh 100% 0941 The temperature of the mixed moisture roll mill on 28-mesh 70% roast and coffee when fed into the roll mill should be about through 28-mesh 30% 35° F. to 40° F. Maintenance of the coffee feed temperature along with maintenance of the roll Surface temperature within the ranges given below insures that aroma losses during the 0935 Typical grinding equipment and methods for grind roll milling step are sufficiently reduced such that the result ing roasted coffee beans are described, for example, in Sivetz & Foote, "Coffee Processing Technology”. Avi Publishing ant flaked coffee has an aroma level sufficient to provide the Company, Westport, Conn., 1963, Vol. 1, pp. 239-250. desired initial aroma layer for flakes of all thicknesses. B. Blending 2. Roll Surface Temperature 0936. The high-moisture roast and ground coffee fraction 0942 Control of the surface temperature of each roll has is blended with the low-moisture roast and ground coffee been found to be important to the provision offlaked roast and fraction to form a mixed-moisture roast and ground feed for ground coffee of high extractability. Roll surface tempera the roll-milling operation. Any Suitable method of admixing ture, as used herein, is measured in degrees Fahrenheit and the coffee fractions which does not involve high shear mixing refers to the average surface temperature of each roll of the can be employed. High shear mixing is unsuitable because roll mill. The rolls can be operated at differential operating shear mixers work the roast and ground coffee causing temperatures. However, operation under conditions of differ increased particle size reduction. ential roll temperatures is not preferred. Best results are 0937. Especially desirable and suitable mixing devices are obtained when each roll is operated at the same temperature. revolving “horizontal plane baffle mixers such as a common 0943. The surface temperature of each of the respective cement mixer; however, the most preferred blenders are fall rolls can be controlled in known manner. This is usually ing chute riffle blenders. A falling chute riffle blender is accomplished by control of the temperature of a heat comprised of a large cylindrical tube-like vessel with down exchange fluid passing through the inner core of the rolls. wardly mounted baffles on the inside walls thereof. To pro 0944. To produce the aggregated, mixed moisture flaked mote gentle tumbling and intermixing, the high-moisture roast and ground coffee of the twelfth group of embodiments, roast and ground coffee particles and the low-moisture roast it is important that the roll surface temperature be within the and ground coffee particles to be admixed are gravity fed range of from 50° F to 80° F., preferably between about 60° through the baffled vessel. F. to 70° F. In general, higher roll surface temperatures pro 0938. It is important to the operation of the method that the duce flakes of roast and ground coffees which typically have roast and ground coffee fractions during the blending step be undesirably low levels of aroma. Lower roll surface tempera maintained at a temperature of below 40°F. Better results are tures require elaborate cooling systems and therefore higher achieved when coffee fractions during blending are main COStS. US 2014/0370181 A1 Dec. 18, 2014 64
3. Roll Diameters art as "choke feeding. When choke feeding occurs, there is a buildup of material which “boils” in the nip region before 0945. The diameter of the roll mills controls the angle of passing through the nip. Such boiling may cause an undesir entry into the nip which in turn affects flake thickness and able effect on the particle size distribution of the flaked coffee bulk density. Rolls smaller than 6 inches in diameter can be product by increasing the percentage of fines and, therefore, employed to flake coffee; however, such small rolls tend to is to be avoided. hamper passage of the coffee through the mill by a churning 0950 Conversely, when the feed rate falls below the theo effect which decreases throughput and efficiency. Roll mills retical throughput rate, the feed rate and throughput rate are with diameters of up to 48 inches are suitable for use herein. the same. This condition is referred to in the art as “starve However, best results are obtained from mills having diam eters in the range of from 6 to 30 inches. Examples of suitable feeding. Starve feeding offers the particular process advan mills which can be adapted in known manner to operate tages as increased equipment life and increased process flex within the parameters defined hereinbefore include any of the ibility and is, therefore, the suitable mode of operation in the well-known and commercially available roll mills such as method of the twelfth group of embodiments. those sold under the tradenames of Lehmann, Thropp, Ross, Farrell and Lauhoff. 7. Roll Peripheral Surface Speed 0951 Control of the peripheral surface speeds of the rolls 4. Static Gap is also believed to be important to the provision of the present aggregated flaked coffee. The roll peripheral Surface speed is 0946. As used herein, the term “mechanical static gap' measured in feet per minute of roll surface circumference represents that distance separating the two roll mills along the which passes by the nip. Generally, the roll mill should be line of nip while at rest and is typically measured in mils. A special condition of roll spacing is “Zero static gap' which is operated at a roll speed of from about 470 ft/min. to 1880 used herein to indicate that the two rolls are in actual contact ft./min., preferably from about 1180 ft./min. to 1650 ft./min. with each other along the line of nip when the roll mills are at 0952 For a given set of roll mill operating conditions, the rest. As roast and ground coffee is fed into the roll mills and throughput rate, the roll peripheral Surface speed and the drawn through the nip, it causes the rolls to deflect an amount thickness of the flaked coffee produced are closely related. In which is dependent upon the roll peripheral speed, roll pres the production of flaked coffee of a specified thickness, the Sure, and coffee feed rate. Accordingly, the aggregated throughput rate is directly related to the roll peripheral surface mixed-moisture flaked coffee of the twelfth group of embodi speed. Thus, an increase in the roll peripheral Surface speed ments can be made even when the roll mills are set at Zero allows an increase in the throughput rate in producing flakes static gap. Because of the deflecting action of the coffee feed of specified thickness. When a constant throughput rate is as it passes through the roll mill, the static gap setting must be maintained (e.g., by controlling the feed rate), higher roll less than the desired flake thickness. Suitable static gap set peripheral Surface speeds produce thinner flakes and con tings range from 0 (i.e., from a Zero gap setting) up to about 1 versely, lower roll peripheral surface speeds produce thicker mil, 0.001 in. flakes. 0947. In the most preferred method of practice, a zero 0953. As the roll peripheral surface speeds increase to static gap spacing of the roll mills is employed. Differential greater than about 1700 ft./min., the production of undesir roll peripheral surface speeds are to be strictly avoided when ably high levels of fines begins to occur. Moreover, high the roll mills are set for Zero static gap operation. Contact peripheral Surface speeds promote temperature increases along the line of nip between rolls operating at differential which can alter and degrade the flavor of the roast and ground peripheral Surface speeds can cause several physical damage flakes produced. to the roll mill. Differential roll peripheral surface speeds can 0954 While peripheral surface roll speeds have been set be utilized, however, with static gap spacings exceeding forth in connection with operation of a roll mill to provide about 1 mil. flaked coffee of improved extractability, it will be appreciated that optimal speeds will be determined in part by the other roll mill conditions such as the size of the rolls employed, the 5. Moisture Content of the Roll Mill Feed static gap setting, etc., as well as the physical and organoleptic 0948. As indicated above, in producing consumer-accept properties desired in the flaked product. able aggregated flaked roast coffee, it is important that the average aggregated flaked moisture content be from about 3% 8. Roll Pressure to 5% by weight. Since the moisture level of the coffee par ticles is not significantly affected by the flaking operation, the 0955 Roll pressure will also influence the nature of the moisture level of the aggregated flaked coffee product herein aggregated, mixed-moisture coffee flakes obtained by the can be controlled by controlling the moisture content of the process of the twelfth group of embodiments. Roll pressure is roast and ground coffee feed. measured in pounds per inch of nip. Nip is a term used in the art to define the length of surface contact between two rolls when the rolls are at rest. To illustrate, it can be thought of as 6. Feed Rate a line extending the full length of two cylindrical rolls and (0949. The feed rate into the roll mill is to be distinguished defining the point or line of contact between two rolls. from the throughput rate of the roll mill. The feed rate to the 0956 To produce the present coffee flake aggregates in roll mill is that amount of material per hour per inch of nip high yield, roll pressures should be within the range of from which is fed into the nip area. The throughput rate is the 150 lbs./linear in. of nip to 4,000 lbs./linear in. of nip and amount of material per hour per inch of nip that actually preferably within the range of from 1,000 lbs./linear in. of nip passes through the roll mill. When the feed rate exceeds the to 2,000 lbs./linear inch of nip. In general, operable feed rates throughput rate, a condition occurs which is referred to in the are directly related to the roll pressure. Thus, higher roll