GB2638955A - Process of manufacturing a product for preparing a beverage - Google Patents

Abstract

A process for manufacturing a product for preparing a beverage comprising: a) spraying an aqueous liquid (preferably water or sugar solution) onto a dry mixture comprising a fibre-containing ingredient and sugar; b) adding beverage ingredient powder(s) to the wetted mixture to attach the beverage ingredient(s) and sugar onto a surface of the fibre-containing ingredient; and c) drying the mixture. Preferably, the fibre-containing ingredient is cocoa with a 400-750μm particle size. Preferably, the beverage ingredient is instant coffee, chocolate powder, milk powder and/or creamer. Preferably, the process includes densifying the fibre-containing ingredient after and/or during step b) to at least 400 g/l. Also claimed is the product of the process, which preferably comprises 15–65wt.% fibre-containing ingredient, 1-60wt.% beverage ingredient(s), 1-35wt.% sugars and 0.1-1.0wt.% flavouring. Preferably, the beverage ingredient powders and sugar discontinuously cover the surface of the fibre ingredient and the mean density of the product is 400-750 g/l. Also claimed are a container for a beverage machine containing the beverage, a method of preparing it, a method of preparing a beverage, and a product for preparing a chocolate beverage.

Description

PROCESS FOR MANUFACTURING A PRODUCT FOR PREPARING A

BEVERAGE

Technical Field of the Invention

The present invention relates to a process for manufacturing a product for preparing a beverage. In particular, the present invention relates to a process for manufacturing a product comprising a fibre-containing ingredient having one or more beverage ingredient powders and sugar attached to a surface of the fibre-containing ingredient.

Background to the Invention

When preparing a beverage containing a number of powdered ingredients, it is known in the art, that powder solubility can he a problem, resulting in a weak tasting watery beverage and an undesirable leftover residue of wetted powder.

A number of options exist to the skilled person when faced with a problem of powder solubility, including, varying the type or blend of solvent, increasing the temperature or volume of the solvent, the introduction of shear or increasing powder-solvent contact time for example. In some applications, such as containers for use in beverage preparation machines, it is known that several of these levers for adjusting solubility are restricted/limited or unavailable.

As such, alternative methods may be used such as the addition of inserts to ensure sufficient solubility during brewing. However, the use of such inserts adds additional costs and waste to the product.

Therefore, it is an aim of the present invention to provide a process for manufacturing a product for preparing a beverage, preferably a chocolate beverage, containing one or more beverage ingredient powders with improved solubility and/or reduced cost and/or reduced waste.

It also an aim of embodiments of the present invention to provide an improved product for preparing a beverage, preferably a chocolate beverage, having reduced level of fines, increased density, lower brew pressure, improved solubility, the ability to brew without the need of an insert, and/or increased amount of brew solids.

It is also an aim of embodiments of the invention to overcome at least one problem of the prior art, whether expressly disclosed herein or not.

Summary of the Invention

According to a first aspect of the present invention, there is provided a process for manufacturing a product for preparing a beverage comprising the steps of: a) spraying an aqueous liquid onto a dry mixture comprising a fibre-containing ingredient and sugar to wet the mixture; b) adding a fibre-containing ingredient and one or more beverage ingredient powders to the wetted mixture to attach the one or more beverage ingredients and sugar onto a surface of the fibre-containing ingredient; and c) drying the mixture formed in step b) to form a product comprising a fibre-containing ingredient having one or more beverage ingredient powders and sugar attached on a surface thereof.

Surprisingly, the inventors observed that adding one or more beverage ingredient powders after the step a) of spraying an aqueous liquid onto a dry mixture of sugar and a fibre-containing ingredient improved the solubility of the resulting product.

Without being hound by theory, it is thought that addition of the beverage ingredient powder after the spraying step prevents early dissolution of the beverage ingredient powder. It is thought that this early dissolution may result in the beverage ingredient powder drying into a less soluble form with reduced available surface area prior to preparation of the product.

Additionally, the inventors found that the process of the present invention attaches the one or more beverage ingredient powders and sugar to the surface of the fibre-containing ingredient rather than coating the fibre-containing ingredient with the beverage ingredient powder and sugar. The attachment of the beverage ingredient powder and sugar onto the surface of the fibre-containing ingredient was seen to provide improved solubility. Without being bound by theory, it is thought that this is because the attachment of the beverage ingredient powder and sugar onto the surface of the fibre-containing ingredient provides a more porous product.

Surprisingly, the inventors also observed that the process also increases the density of the product. Beneficially, this reduces the volume of product required to achieve a desired flavour thereby providing a reduction in packaging volume and a reduction in the amount of product required. Moreover, the inventors have observed that the process also results in a product with improved tlowability. Beneficially, this makes transportation and filling of the product easier during production.

The fibre-containing ingredient may comprise soluble dietary fibre, insoluble dietary fibre or both.

The fibre-containing ingredient may be selected from the group consisting of sugarcane fibre, wheat, pea fibre, potato, oats, cocoa beans, cocoa (press) cake, cocoa mass, cocoa nibs, cocoa bean shells (also known as cocoa nib shells), cocoa pod husk (also called cocoa pod shells), ground cocoa bean shells (also known as ground cocoa nib shells), ground cocoa pod husk, cocoa powder, granulated cocoa powder and any combination thereof.

Preferably, the fibre-containing ingredient is selected from the group consisting of sugarcane fibre-containing, ground cocoa bean shells (also known as ground cocoa nib shells), ground cocoa pod husk, granulated cocoa powder and combinations thereof.

Preferably, the fibre-containing ingredient does not comprise coffee or a coffee derived ingredient.

Preferably, the fibre-containing ingredient is a cocoa ingredient.

The cocoa ingredient may be any ingredient comprising cocoa.

The cocoa ingredient may be an ingredient selected from the group consisting of cocoa beans, cocoa (press) cake, cocoa mass, cocoa nibs, cocoa bean shells (also known as cocoa nib shells), cocoa pod husk (also called cocoa pod shells), ground cocoa bean shells (also known as ground cocoa nib shells), ground cocoa pod husk, cocoa powder, granulated cocoa powder and any combination thereof.

Preferably, the cocoa ingredient is selected from the group consisting of ground cocoa bean shells (also known as ground cocoa nib shells), ground cocoa pod husk, granulated cocoa powder and combinations thereof.

The fibre-containing ingredient may have a particle size of at least 200 p m, 225 pm, 250 pm, 275 pm, 300 pm, 325 pm, 350 pm, 375 pm, 400 pm, 425 pm, 450 pm, 475 pm, 500 pm, 525 pm, 550 pm, 575 pm, 600 pm, 625 pm, 650 pm, 675 pm, or at least 700 pm.

The fibre-containing ingredient may have a particle size of no more than 1000 p m, 975 p m, 950 p m, 925 p m, 900 p m, 875 p m, 850 p m, 825 p m, 800 p m, 775 p m, 750 p m, 725 p m, 700 p m, 675 p m, 650 p m, 625 p m, 600 p m, 575 pm, 550 p m, 525 pm, or no more than 500 pm.

The fibre-containing ingredient may have a particle size of from 200 -1000 p m, 225 -975 pm, 250 -950 pm, 275 -925 pm, 300 -900 pm, 325 -900 pm, 350 -900 pm, 375 -900 pm, 400 -900 pm, 400 -875 pm, 400 -850 pm, 400 -825 pm, 400 800 pm, 400 -775 pm, 400 -750 pm, 425 -750 pm, 450 -750 pm, 475 -750 pm, 500 -750 pm, 525 -750 pm, 550 -750 pm, 550 -725 pm, or from 550 -700 pm.

Preferably, the fibre-containing ingredient has a particle size of from 400 -750 pm.

Surprisingly, the inventors found that a fibre-containing ingredient having the above preferred particle sizes demonstrated improved solubility when brewed whilst still providing an acceptable brew pressure without unacceptable pressure drops.

The fibre-containing ingredient may have a fines percentage of no more than 20 %, 19 %, 18 %, 17 %, 16 %, 15 %, 14 %, 13 %, 12 %, 11 %, 10 %, 9 %, 8 %, 7 %, 6 %, 5 %, 4 %, 3 %, or no more than 2 %.

The fines may be measured, for example, by laser diffraction particle size measurement (e.g. Helos/KR (Sympatec) system measured with R7 lens). The term "fines" is used herein to refer to particles less than 90 microns, sometimes described as 25 Q90.

The fibre-containing ingredient may have a fines percentage of 1 -20 %, 1 -19 %, 1 -18 %, 1 -17 %, 1 -16 %, 1 -15 %, 1 -14 %, 1 -13 %, 1 -12 %, 1 -11 %, 1 -10 %, 1 -9 %, 1 -8 %, 2 -20 %, 2 -19 %, 2 -18 %, 2 -17 %, 2 -16 %, 2 -15 %, 2 -14 %, 2 -13 %, 2 -12 %, 2 -11 %, 2 -10 %, 2 -9 %, or from 2 -8 %.

The sugar may he selected from the group comprising a monosaccharide, disaccharide and/or an oligosaccharide. The sugar may be one or more sugars selected from the group consisting of glucose, sucrose, fructose, galactose, lactose, maltose, molasses and combinations thereof.

The one or more beverage ingredient powders may comprise a powder selected from the group consisting of an instant coffee powder, a chocolate powder, a milk powder, dairy creamer, a non-dairy creamer powder, and combinations thereof. In preferred embodiments, the beverage ingredient powder comprises fat. In a more preferred embodiments, the beverage ingredient powder is a fat-containing powder selected from a chocolate beverage powder, a milk powder and a non-dairy creamer powder.

In the case of the beverage ingredient powder comprising a chocolate powder, the inventors discovered that the attachment of a chocolate powder on the surface of the fibre-containing ingredient may allow the chocolate powder to enter the brew more readily.

"Non-dairy creamer" refers to a product that replicates the mouthfeel and/or flavour of dairy milk and comprises a fat or oil and optionally an emulsifier, a protein and/or a sweetener. The fat is typically a non-dairy fat, preferably a vegetable fat, such as coconut oil, olive oil, grapeseed oil, cocoa butter, palm oil, palm kernel oil, sunflower oil, and rapeseed oil. Any appropriate food grade protein and sweetener may he used in the composition. The non-dairy creamer may comprise a dairy protein, such as sodium caseinate.

"Dairy creamer" refers to products known commercially as 'Dairy creamer'. They are typically compositions that comprise at least a fat and optionally an emulsifier, a protein and/or a sweetener. Any appropriate food grade protein and sweetener may be used in the composition. Typically, the fat is a dairy fat and the protein is a dairy protein, such as sodium cascinatc.

"Chocolate powder" refers to any powder comprising cocoa. It may further comprise additional ingredients such as a milk powder, a fat; a sweetener, hulking agent, drying agent, anti-caking agent; etc. The fat may be cocoa butter, cocoa butter equivalent, cocoa butter substitute or any animal or plant derived fat. The sweetener may be selected from a carbohydrate-based sweetener or a non-carbohydrate based sweetener. The carbohydrate-based sweetener may be one or more selected from the group comprising a sugar such as fructose, glucose, maltose, sucrose, lactose, dextrose, high fructose corn syrup or a sugar substitutes like e.g. polyols such as sorhitol, mannitol, xylitol or combinations thereof, maltodextrins, dried glucose syrups, malt extracts, starches, trehalose, raftiline, raftilose, galactose, maltose, oligosaccharides, honey powders, and mixtures of same. The non-carbohydrate based sweetener may be an artificial sweetener like e.g. Splenda0, Acesulfame K0, or aspartame, and mixtures of the same. The non-carbohydrate based sweetener may be a natural sweetener, such as stevia.

"Milk powder" refers to a composition that comprises at least milk from animal sources, such as, goats, cows, sheep, etc., and milk alternatives derived from plant sources, including those derived from nuts; oats; seeds; drupes, grains, including, but not limited to, almond, cashew, soybean, coconut, hemp, rice, horchata, peanut. It may be derived from full fat, semi-skimmed, skimmed, heat treated, homogenised milk etc. In particular, it may be full fat. milk powder, semi skimmed milk powder and/or skimmed milk powder.

The instant coffee powder may be derived from the group consisting of pure 20 Arabica whole coffee beans, pure Robusta whole coffee beans and combinations thereof.

In embodiments in which the beverage ingredient powder comprises fat, it comprises at least 5%, 6%, 7%, 8%, 9% or 10%wt fat and/or no more than 70%, 60%, 50%, 30%, or 20wt.% fat, and/or between 5 -40 wt.%, 6 -39 wt.%, 7 -38 wt.%, 8 - 37 wt.%, 9 36 wt.%, 10 35 wt.%, 11 34 wt.%, 12 33 wt.%, 13 32 wt.%, 14 31 wt.%, 15 -30 wt.%, 16 -29 wt.% 17 -28 wt.%, 18 -27 wt.%, 19 -26 wt.%, 20 - wt.%, 25 -70 wt.%, 26 -69 wt.%, 27 -68 wt.%, 28 -67 wt.%, 29 -66 wt.%, 30 - wt.%, 31 -64 wt. %o, 32 -63 wt.% 33 -62 wt. %, 34 -61 wt.%, 35 -60 wt.%, 36 - 59 wt.%, 37 -58 wt.%, 38 -57 wt.%, 39 -56 wt.%, 40 -55 wt.%, 41-54 wt.%, 42 - 53 wt.%, 43 -52 wt.%, 44 -51 wt.%, 45 -50 wt.%, preferably between 10% -25%wt, -25 wt.%, 25 -70 wt.%, or 45 -50 wt.% fat by weight.

In embodiments, where the beverage ingredient powder is chocolate powder; it comprises at least 4%, 4.5%, 5%, 5.5% or 6wt.% fat and/or no more than 20 %, 19 %, 18 %, 17 %, 16 %, 15 %, 14 %, 13 %, 12 %, 11 %, 10 %, 9%, 8.5%, 8%, 7.5% or 7%wt fat and/or between 4 -20 %, 4 -19 %, 4 -18 %, 4 -17 %, 4 -16 %, 4 -15 %, 4 -14 %, 4 -13 %, 4 -12 %, 4 -11 %, 4 -10 %, 4% -9%wt; 4% -8%wt; 4% -7%wt; 5% - 9wt.%; 5% -8wt.% or 6% -8wt.% fat.

In further embodiments, where the beverage ingredient powder is a milk powder, it comprises at least 10%, 11% or 12wt.% and/or no more than 30%, 25%, 22% or 20wt.% fat and/or between 10% -25wt.%, 10% -20wt.%, 12% -25wt.% or 12% - 20wt.% fat. In further embodiments, where the beverage ingredient powder is a dairy creamer powder or a non-dairy creamer powder, it comprises at least 25wt.% and/or no more than 70wt.% fat and/or between 25% -70wt.% fat.

Beverage powders that contain fat in such quantities as described here are known in the art to have lower solubility in water. Embodiments of the invention that have such fat content have the particular advantage of sufficient solubility to create a beverage with adequate solids content and low beverage ingredient residues.

Steps b) and c) may be carried out simultaneously.

In some embodiments, steps I)) and c) may he carried out simultaneously. Alternatively, steps b) and c) may be carried out sequentially.

The aqueous liquid may be water or an aqueous solution.

The aqueous solution may be a sugar solution.

The sugar may be a monosaccharide, disaccharide and/or an oligosaccharide.

The aqueous solution may be an aqueous solution comprising glucose, sucrose, fructose, galactose, lactose and/or maltose.

Preferably, the aqueous liquid is water.

The process may further comprise a step of adding additional sugar.

Preferably, the step of adding additional sugar may he performed after step 1)) and before step c).

The process may further comprise the step of adding a flavouring. The step of adding a flavouring may be before step a).

In other embodiments of the invention the step of adding a flavouring may he after step a) and before step b).

hi other embodiments, the step of adding a flavouring may be performed sequentially at the same time as step a) or step b).

In other embodiments still, the step of adding a flavouring may he performed after step b) and before step d).

Preferably, the flavouring is added before step a).

The flavouring may be selected from the group consisting of chocolate (or cocoa), vanilla, salt, strawberry, cinnamon_ mint, hazelnut, caramel, and combinations thereof.

The step of spraying the aqueous liquid may comprise spraying an aqueous liquid in an amount of at least 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, lOwt.%, 11, 12 wt.%, 13 wt.%, 14 wt.%, 15wt.%, or at least 20wt.% by weight of the product during step a).

The step of spraying the aqueous liquid may comprise spraying an aqueous liquid in an amount of no more than 30wt.%, 20wt.%, 15 wt.%, or no more than lOwt.% by weight of the product during step a).

The step of spraying the aqueous liquid may comprise spraying an aqueous liquid in an amount of from 1-40wt.%, 1-35wt.%, 1-30wt.%, 1-25wt.%, 5-25wt.%, 10-25wt.%, 15-25wt.%, 15-25wt.%, 1-20wt.%, 1-15 wl.%, 5-20wt.%, 5-15wt.%, 10-20wt.%, or 10-15wt.% by weight of the product during step a).

The step of adding one or more beverage ingredient powders may comprise adding one or more beverage ingredient powders in an amount of at least 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, lOwt.%, 11, 12 wt.%, 13 wt.%, 14 wt.%, 15wt.%, 20wt.%, 25wt.%, 30wt.%, 35wt.%, 40wt.%, 45wt.% 50wt.%, 55wt.% or at least 60wt.% by weight of the mixture formed in step b). The step of adding one or more beverage ingredient powders may comprise adding one or more beverage ingredient powders in an amount of no more than 60wt.%, 55wt.%, 50wt.%, 45wt.%, 40wt.%, 35wt.%, 30wt.%, 25wt.%, 20wt.%, 15wt.% or no more than lOwt.% by weight of the mixture formed in step b).

The step of adding one or more beverage ingredient powders may comprise 5 adding one or more beverage ingredient powders in an amount of from 1-60wt.%, 1-50wt.%, 1-45wt.%, 1-40wt.%, 1-35wt.%, 5-40wt.%, 10-40vvt.%, 15-40vvt.%, 20-40wt.%, 25-40vvt.%, or 30-40wt.% by weight of the mixture formed in step b).

The dry mixture may comprise a fibre-containing ingredient in an amount of from at least 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5vvt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, lOwt.%, 11,12 wt.%, 13 wt.%, 14 wt.%, 15wt.%, 20wt.%, 25wt.%, 30wt.%, 35wt.%, 40wt.%, 45wt.%, 50wt.%, or at least 60 wt.%, by weight of the dry mixture.

The dry mixture may comprise a fibre-containing ingredient in an amount of no more than 99wt.%. 98wt.%, 96wt.%, 95wt.%, 94wt.%, 92wt.%, 90wt.%, 88wt.%, 86wt.%, 85wt.%, 80wt.%, 75 wt.%, 70wt.%, 65wt.% or no more than 60wt.% by weight of the mixture.

The dry mixture may comprise a fibre-containing ingredient in an amount of from 1-99wt.%, 1-95wt.%, 1-90wt.%, I-85wt.%, 1-80wt.%, 1-75wt.%, 1-70).vt.%, 1-65wt.%, 10-65wt.%, 15-65wt.%, 20-65wt.%, 25-65wt.%, 30-65wt.%, 35-65wt.%, 40-65wt.%, or 45-55wt.% by weight of the dry mixture.

The dry mixture may comprise a sugar in an amount of at least 5 wt.%, lOwt.%, or at least 15wt.% by weight of the dry mixture. The dry mixture may comprise a sugar in an amount of no more than 25wt.%, 20wt.%, 19wt.%, 18wt.%, 17wt.%, 16wt.% or no more than 15wt.% by weight of the dry mixture.

The dry mixture may comprise a sugar in an amount of 1-30).vt.%, 1-25wt.%, 5- 25wt.%, 10-25wt.%, 10-20wt.%, 11-19wt.%, 12-18wt.% or 13-17wt.% by weight of the dry mixture.

Step a) of spraying the aqueous liquid may have a time of at least 10 seconds, 20 seconds, 30 seconds, 40 seconds, 50 seconds, 1 minute, 2 minute, 3 minutes, 4, minutes, 5 minutes, 6 minutes, 7 minutes or 8 minutes. In some embodiments, step a) may have a time of no more than 12 minutes, 11 minutes, 10 minutes, 9 minutes, 7 minutes, 6 minutes, 5 minutes, 4 minutes, 3 minutes, 2 minutes, or 1 minutes.

Step a) of spraying the aqueous liquid may have a time of 10 seconds -12 minutes, 20 seconds -12 minutes, 30 seconds -12 minutes, 40 seconds -12 minutes, 50 seconds -12 minutes, 1 minutes -12 minutes, 3 -12 minutes, 4 -11 minutes, 5 -minutes, 6 -10 minutes, 7 -10 minutes, 8 -10 minutes, 5 -9 minutes, 5 -8 minutes, 5 -7 minutes, 10 seconds -5 minutes, 10 seconds -4 minutes, 10 seconds -3 minutes, 10 seconds -2 minutes, 20 seconds -2 minutes, 30 seconds -2 minutes, or 30 seconds -1 minute.

In some embodiments, the aqueous liquid may have a viscosity of at least 5 mPas, 10 mPas, 15 mPas, 20 mPas, 25 mPas, 30 mPas, 40 mPas, 50 mPas, 60 mPas, 70 mPas, 80 mPas, 90 rnPas or 100 mPas. The aqueous liquid may have a viscosity of no more than 100 mPas, 90 mPas, 80 mPas, 70 mPas, 60 mPas, 50 mPas, 40 mPas, 35 mPas, 30 mPas, 25 mPas or 20 mPas.

The aqueous liquid may have a viscosity of 5 -100 mPas, 5 -90 mPas, 10 -80 mPas, 10 -70 mPas, 10 -60 mPas, 10 -50 mPas, 10 -40 mPas, 15 -30 mPas, 20 30 mPas, 10 -25 mPas or 10 -20 mPas.

Embodiments with such parameters have the additional advantage of low level of fines in the product.

In one embodiment, steps a), b) and/or c) may comprise mixing.

Preferably, steps a), b) and c) comprise mixing.

In such embodiments, steps a), I)) and/or c) may comprise mixing for a period of at least 50 seconds, 60 seconds, 70 seconds, 80 seconds, 90 seconds, 100 seconds, 110 seconds, 120 seconds, 130 seconds 140 seconds 150 seconds, 160 seconds, 170 seconds, 180 seconds, 200 seconds, 225 seconds, 250 seconds, 275 seconds, 300 seconds, 325 seconds, 350 seconds, 375 seconds, 400 seconds, 425 seconds, 450 seconds, 475 seconds, 500 seconds, 525 seconds, 550 seconds, 575 seconds, or 600 seconds. 1l

It has been observed that such mixing times enables the one or more beverage ingredient powders and sugar to be attached across a larger surface of the fibre-containing ingredient. This improves the solubility of the product during brewing.

Steps a), b) and/or c) may comprise mixing at a tip speed of at least 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 2.0 m/s, 2.2, 2.4 or 2.5 m/s. In some embodiments, step c) may have a tip speed of no more than 5.0, 4.8, 4.6, 4.4, 4.2, 4.0, 3.8, 3.6, 3.4, 3.2, 3.0, 2.8, 2.6, 2.4, 2.2 or 2.0 m/s.

Step a), b) and/or c) may comprise mixing at a tip speed of 0.5 -5 m/s, 0.5 -4 m/s, 0.5 -3 m/s, 0.5 -2.5 m/s, 0.5 -2.0 m/s, 1.0 -2.0 m/s.

It has been observed that such mixing speeds increases the density of the product. This improves the solubility of the product and increases the fill weight of the product.

The process may further comprise the step of densifying the fibre-containing ingredient after and/or during step 1)).

The step of densifying the fibre-containing ingredient may be before step c).

The step of densifying the fibre-containing ingredient may be before step c) and after step b).

The densification of the fibre-containing ingredient forms stronger and more dense agglomerates of the fibre-containing ingredient. These stronger and/or more dense agglomerates are less likely to break up. Without being bound by theory, it is thought that densification of the fibre-containing ingredient allows water to be better distributed over the product during brewing, thereby improving solubility.

Moreover, the densification step increases the density of the product, thereby increasing the total amount of product that can he added to a container, such as a 25 capsule.

The step of densifying the fibre-containing ingredient may comprise increasing the density of the fibre-containing ingredient.

The step of densifying the fibre-containing ingredient may comprise increasing the density of the fibre-containing ingredient to at least 200 g/1, 225 WI, 250 g/1, 275 g/l, 300 g/1, 325 g/1, 350 WI, 375 g/1, 400 g/I, 425 g/1, 450 g/1, 475 WI, 500 g/I, 525 g/I, 550 g/1, 575 g/1, or at least 600 g/1..

The step of densifying the fibre-containing ingredient may comprise increasing the density of the fibre-containing ingredient to no more than 900 WI, 875 g/I, 850 g/I, 825 g/1, 800 g/1, 775 g/1, 750 g/1, 725 g/l, 700 g/1, 675 g/1, 650 g/1, 625 g/1, 600 g/1, 575 g/l, 550 g/I, 525 g/l, or no more than 500 g/1..

The step of densifying the fibre-containing ingredient may comprise increasing the density of the fibre-containing ingredient of from 200 -900 g/l, 225 -875 g/1, 250 850 2/1, 275 -825 g/I, 300 -800 g/I, 325 -775 g/l, 350 -750 g/I, 375 -750 g/I, or from 400 -750 g/1.

The step of densifying the fibre-containing ingredient may comprise subjecting the fibre-containing ingredient to shear mixing.

The shear mixing may be high shear mixing and/or low shear mixing.

The step of densifying the fibre-containing ingredient may be carried out for at least 50 seconds, 60 seconds, 70 seconds, 80 seconds, 90 seconds, 100 seconds, 110 seconds, 120 seconds, 130 seconds 140 seconds 150 seconds, 160 seconds, 170 seconds, or 180 seconds, 200 seconds, 250 seconds, 300 seconds, 350 seconds, 350 seconds, 400 seconds, 450 seconds, 500 seconds or at least 550.

The process may further comprise a step of filling a mixing device with sugar.

The step of filling the mixing device may be before step a).

The step of filling the mixing device may comprise filling the mixing device to at least 10%, 20%, 30%, 40%, 45%, 50%, 55%, 60%, 65% 70%, 75% 80, or 90% of its total volume. The step of filling the mixing device may comprise filling the mixing device to no more than 90%, 80%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, or 30% of its total volume.

In some embodiments, the step of filling the mixing device may comprise filling the mixing device to from 53-60%, 54-60%, 54-60%, 50-59%, 50-58%, 50-57%, 5056%, or 50-55% of its total volume.

The inventors discovered that if the mixing device is not filled to its total volume, the step of densifying the fibre-containing ingredient may result in fluidised particle motion. This may result in the formation of a mechanically induced fluidised bed.

Beneficially, the partial filling of the mixing device allows improved control of the density of the final product. For example, partial filling of the mixing device may provide a lower density product, whereas the complete filling of the mixing device may provide a higher density product.

Therefore, the step of densifying the fibre-containing ingredient may comprise mechanically fluidising a bed of the fibre-containing ingredient, beverage ingredient and sugar.

The mixing device may he a granulator.

The mixing device may be a high shear granulator or a low shear granulator. Preferably, the mixing device is a high shear granulator.

Beneficially, a high shear granulator is able to carry out at least steps a) to c) and preferably all of the process steps in one device. Moreover, a high shear granulator has been found to provide a product with an appropriate friability and density.

In sonic embodiments, the step of filling the mixing device may comprise filling the mixing device to 10-90%, 20-80%, 30-70%, 40-70%, 45-70%, 45-65%, 45-60%, 20 45-55%, 50-60%, 45-60%, 46-60%, 47-60%, 48-60%, 49-60%, 50-60%, 51-60%, 5260%.

According to a second aspect of the present invention, there is provided a product for preparing a beverage obtainable by the process according to the first aspect of the invention.

The product may comprise a fibre-containing ingredient in an amount of at least 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, lOwt.%, 11, 12 wt.%, 13 wt.%, 14 wt.%, 15vvt.%, 20wt.%, 25wt.%, 30vvt.%, 35wt.%, 40wt.%, 45wt.%, 50wt.%, 60 wt.%, 65 wt.%, 70 wt.%, or 75 wt.%, by weight of the product. The product may comprise fibre-containing ingredient in an amount of no more than 99wt.%, 98wt.%, 96wt.%, 95wt.%, 94wt.%, 92wt.%, 90wt.%, 88wt.%, 86wt.%, 85wt.% 80wt.%, 75wt.%, 70 wt.%, 65wt.%, 60wt.% or no more than 55wt.% by weight of the product.

The product may comprise fibre-containing ingredient in an amount of from 1- 99wt.%, 1-95wt.%, 1-90wt.%, 1-85wt.%, 10-85wt.%, 15-75wt.%, 15-70wt.%, 15- 65wt.%, 20-65wt.%, 25-65wt.%, 30-65wt.%, 30-60wt.%, 30-55wt.%, 30-50wt.%, or 35-45wt.% by weight of the product.

The product may comprise one or more beverage ingredient powders in an amount of at least 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, lOwt.%, 11, 12 wt.%, 13 wt.%, 14 wt.%, 15wt.%, 20wt.%, 25wt.%, 30wt.%, 35wt.%, 40wt.%, 45wt.% or at least 50wt.% by weight of the product.

The product may comprise one or more beverage ingredient powder in an amount of no more than 60wt.%, 55wt.%, 50wt.%, 45wt.%, 40wt.%, 35wt.%, 30wt.%, 25wt.%, 20wt.%, 15wt.% or no more than lOwt.% by weight of the product.

The product may comprise one or more beverage ingredient powders in an amount of from 1-60wt.%, 1-55wt.%, 1-50wt.%, 1-45wt.%, 1-40wt.%, 1-35wt.%, 1-30wt.%, 1-25wt.%, 5 -55wt.%, 10 -50vvt.%, 15 -45wt.%, 20 -40wt.%, 25 -45wt.%, 25 -40 wt.% or 30 -40wt.% by weight of the product.

The product may comprise sugar in an amount of at least 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, lOwt.%. 11, 12 wt.%, 13 wt.%, 14 wt.%, 15wt.%, or at least 20wt.% by weight of the product. The product may comprise sugar in an amount of no more than 60wt.%, 55wt.%, 50wt.%, 45wt.%, 40wt.%, 35wt.%, 30wt.%, 25wt.%, 20wt.%, 15vvt.% or no more than lOwt.% by weight of the product.

The product may comprise sugar in an amount of from 1-35wt.%, 1-35 wt.%, 5- 35wt.%, 10-35vvt.%,15-35wt.%, 20-35wt.%, or 25-35wt.% by weight of the product.

The product may comprise a flavouring in an amount of at least 0.01wt.%, 0.02wt.%, 0.03wt.%, 0.04wt.%, 0.05wt.%, 0.06wt.%, 0.07wt.%, 0.08wt.%, 0.09wt.%, 0.10vvt.%, 0.11 wt.%, 0.12wt.%, 0.13wt.%, 0.14vvt.%, 0.15wt.%, or at least 0.20wt.% 30 by weight of the product. The product may comprise a flavouring in an amount of no more than 1.0wt%, 0.90wt%, 0.80wt%, 0.70wt%, 0.60wt.%, 0.55wt.%, 0.50wt.%, 0.45wt.%, 0.40wt.%, 0.35wt.%, 0.30wt.%, 0.25wt.%, 0.20wt.%, 0.15wt.% or no more than 0.10wt.% by weight of the product.

The product may comprise a flavouring in an amount of from 0.01-1.0vvt.%, 0.05-1.0wt.%, 0.1-1.0wt.%, 0.2-1.0wt.%, 0.3-1.0wt.%, 0.5-1.0wt.%, or 0.6-1.0wt.% by weight of the product.

The one or more beverage ingredient powders and sugar may be attached over at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39. 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, or 99% of the surface of the fibre-containing ingredient.

In some embodiments, the one or more beverage ingredient powders and sugar may discontinuously cover the surface of the fibre-containing ingredient.

The beverage ingredient powders and sugar may form granules. particles or agglomerated particles on the surface of the fibre-containing ingredient.

There may he gaps between at least some of the granules, particles or agglomerated particles.

Some granules, particles or agglomerated particles may abut or be partially melded, whilst others are separate and not touching other granules, particles or agglomerated particles.

In some embodiments the one or more beverage ingredient powders and sugar may form a porous network of granules, particles or agglomerated particles on the surface of the fibre-containing ingredient.

The beverage ingredient powder and sugar attached onto the surface of the fibre-containing ingredient may have a mean thickness of at least 0.1 micron, 0.5 microns, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64 or 65 microns.

The beverage ingredient powder and sugar attached onto the surface of the fibre-containing ingredient may have a mean thickness of no more than 250, 245, 240, 235, 230, 225, 220, 215, 210, 205, 200, 195, 190, 185, 180, 175, 170, 165, 160, 155, 150, 145, 140, 135, 130, 125 120, 115, 110, 105, 100, 95, 90, 85, 80, 75, 70, 65, 60, 55 or 50 microns.

In some embodiments, the beverage ingredient powder and sugar attached onto the surface of the fibre-containing ingredient may have a mean thickness of from 1 microns to 250 microns, 5 microns to 200 microns, 10 microns to 150 microns, 10 microns to 125 microns, 10 microns to 100 microns, 10 microns to 100 microns, 15 microns to 100 microns, 20 microns to 100 microns, 25 microns to 100 microns, 30 microns to 100 microns, 35 microns to 100 microns, 40 microns to 95 microns, 40 microns to 90 microns, 40 microns to 85 microns, 40 microns to 80 microns, 45 microns to 75 microns, 45 microns to 75 microns or 50 microns to 75 microns.

Preferably, the thickness of the coating is uniform over the surface of the fibre-containing ingredient.

The product may have a mean density of at least 200 WI, 225 WI, 250 g/l, 275 g/1, 300 g/l, 325 g/I, 350 g/I. 375 g/1, 400 g/I, 425 g/l, 450 WI. 475 g/I. 500 g/I, 525 g/1. 550 a/1, 575 g/l, or at least 600 g/l.

The product may have a mean density of no more than 900 g/l, 875 g/1, 850 WI, 825 g/I, 800 g/I, 775 g/1, 750 g/I, 725 g/l, 700 g/1, 675 g/I, 650 g/I, 625 g/1, 600 g/I, 575 a/1, 550 g/l, 525 a/1, or no more than 500 g/l.

The product may have a mean density of from 200 -900 g/1, 225 -875 g/I, 250 -850 g/I, 275 -825 g/1, 300 -800 g/1, 325 -775 g/I, 350 -750 g/1, 375 -750 g/1, or from 400 -750 g/l.

Densities within these limits provide the additional advantage of optimised pack density within the confines of a machine insertable container, such as a capsule.

The product may have a median or mean particle size of at least 200, 210, 220, 225, 230, 240, 250, 260, 270, 275, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, or at least 600 microns.

The product may have a median or mean particle size of no more than 1000, 980, 970, 960, 950, 940, 930, 920, 910, 900, 890, 880, 870, 860, 850, 840, 830, 820, 810, 800, 790, 780, 770, 760, 750, 740, 730, 720, 710, 700, 690, 680, 670, 660, 650, 640, 630, 620, 610, 600, 590, 580, 570, 560, 550, 540, 530, 520, 510, 500, 490, 480, 470, 460. 450, 440, 430, 420, 410, or no more than 400 microns.

The product may have a median or mean particle size of from 200 -1000 p m, 225 -975 p m, 250 -950 p m, 275 -925 p m. 300 -900 p m, 325 -900 p m, 350 -900 pm, 375 -900 pm, 400 -900 gm, 400 -875 pm, 400 -850 pm, 400 -825 pm, 400 800 pm. Median particle size may be measured by laser diffraction method (e.g. Helos/KR (Sympatec) system measured with R7 lens).

The product may have an amount of fine particles ("fines", particles less than 90 microns, sometimes described as Q90) of no more than 20, 19, 18, 16, 14, 12, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3% of the product. In some embodiments the amount of fines is between 0-20%, 0- 15%, 0-10%, 0-5%, 0-4%, 0-3%, 0-2%, 0-1.9%, 0-1.8%, 0-1.7%, 0-1.6%, 0-1.5%, 0- 1.4%, 0-1.3%, 0-1.2%, 0-1.1%, 0-1.0%, 0-0.9%, 0-0.8%, 0-0.7%, 0-0.6%, 0-0.5%, 00.4%, 0-0.3%, %, 0.1-1.5%, 0.1-1.4%, 0.1-1.3%, 0.1-1.2%, 0-1.1%, 0.1-1.0%, 0.10.9%, 0.1-0.8%, 0.1-0.7%, 0.1-0.6%, 0.1-0.5%, 0.1-0.4%, 0.1-0.3%. The fines may be measured, for example, by laser diffraction particle size measurement (e.g. Helos/KR (Sympatec) system measured with R7 lens).

Embodiments with such levels of fines have the particular advantage of improved solubility over products with alternative levels of fines. Moreover, the low level of fines prevents blocking of a container, such as a coffee container.

The product may have a porosity of at least 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, or at least 0.5.

The product may have a porosity of no more than 0.9, 0.85, 0.8, 0.75, 0.7, 0.65, or no more than 0.6.

In one embodiment, the product may have a porosity of from 0.1 -0.9, 0.15 - 0.85,0.2-0.8,0.2.5-0.75,0.3-0.7,0.35-0.65,0.4-0.6, or from 0.5 -0.6. I8

The porosity may he calculated from particle density and bulk density. For example, the Porosity may be measured by using the following equation: Porosity = (1 -Bulk density/Particle density) The Particle density may be measured using an Accupyc 1300 Helium Pycnometcr.

According to a third aspect of the invention, there is provided a container comprising the product of the second aspect of the invention.

The container is preferably a beverage preparation machine insertable container.

In some embodiments, the beverage preparation machine insertable container is selected from: a capsule, a disc, a pod, a pad, a semi-rigid pad, a filter bag, a pouch, a cartridge.

Preferably, the beverage preparation machine insertable container is a pod or pad.

hi some embodiments, the container may not be a machine insertable container.

hi such embodiments, the container is selected so that the contents may be poured or emptied into a beverage preparation machine.

hi such embodiments, preferably, the container may be a sachet.

hi some embodiments, the container has a volume of at least 5 ml, 10m1, 25 ml, 50m1, 75 ml, 100 ml, 150m1, 175 ml, 200 ml, 225 ml, 250 ml, 275 ml, 300 ml, or at least 325 ml. Preferably, the container has a volume of between 50-350m1. hi more preferred, embodiments, the beverage preparation machine insertable beverage ingredient container comprises a coffee preparation machine -readable portion.

Embodiments with such container volumes have the additional advantages of compatibility with beverage preparation machines, such as coffee machines.

In some embodiments, the product occupies at least 45%, 50%, 55%, 60%, 65%, 70%, 75% or 80% and/or no more than 95% or 90% of the total volume of the container. In some preferred embodiments the product occupies between 45% -95%, or between 55% -95%, or between 65% -95%, or between 75% -95%, or between 45% -90%, or between 55% -90%, or between 65% -90% or between 75% -90% of the total volume of the container.

The preferred ranges of the density and median particle size described above for the first aspect of the invention enable significant volume of filling, whilst also preventing blocking of the container and providing improved solubility. This allows the container to provide a beverage improved texture and concentration whilst having a reduced amount of undesirable leftover residue of wetted powder.

According to a fourth aspect of the invention there is provided a method of preparing a container of a third aspect of the invention comprising steps of: a) providing a product produced according to the second aspect of the present invention; and b) adding the product to a container according to the third aspect of the present invention.

In some embodiments, the container is subsequently sealed, preferably by heat sealing.

According to a fifth aspect of the invention, there is provided a method of preparing a beverage comprising the steps of; a) providing a product of the second aspect of the invention; b) transporting fluid through the product; and c) dissolving and/or suspending at least some of the product in the fluid such that the fluid comprises at least a portion of the product dissolved and/or suspended therein.

In some embodiments, step a) may comprise providing a container of the third aspect of the invention.

hi such embodiments, the method may further comprise a step of emptying the product from the container into a beverage preparation machine after step a) and before step b).

Alternatively, the method may further comprise a step of inserting the container into a beverage preparation machine after step a) and before step b).

In the above embodiments, step c) comprises dissolving and/or suspending at. least some of the product in the fluid such that the fluid exiting the beverage preparation machine comprises at least a portion of the product dissolved and/or suspended therein.

In some embodiments, the volume of fluid transport in step b) is at least 10m1, 25 ml, 50m1, 75 ml, 100 ml, 150m1, 175 ml, 200 ml, 225 ml, 250 ml, 275 ml, 300 ml, or at least 325 ml.

The volume of fluid transport in step b) may, for example be between 50m1 -350 ml.

In some embodiments, the fluid transported in step b) is transported under a pressure of less than 25 bar, 22 bar, 20 bar, 18 bar, 16 bar, 14 bar, 12 bar, 10 bar, 8 bar, 6 bar, 4 bar, 3 bar or 2 bar. In some embodiments, the fluid is transported in step b) under a pressure of at least 0.5 bar, 1 bar or 2 bar. Preferably, the fluid is transported at a pressure of 0.5-3 bar, 1-3 bar or 1-2 bar.

The time taken for steps b) to c) may be less than 300 seconds, less than 275 seconds, less than, 250 seconds, less than 225 seconds, less than 200 seconds, less than 190 seconds, less than 180 seconds, less than 175 seconds, less than 170 seconds, less than 165 seconds, less than 160 seconds, less than 155 seconds, less than 150 seconds, less than 145 seconds, less than 140 seconds, less than 135 seconds, less than 130 seconds, less than 125 seconds, less than 120 seconds, less than 115 seconds, less than 110 seconds, less than 105 seconds, less than 100 seconds, less than 95 seconds, less than 90 seconds, less than 85 seconds, less than 80 seconds, less than 75 seconds, less than 70 seconds, less than 65 seconds, less than 60 seconds, less than 55 seconds, less than 50 seconds, less than 45 seconds, less than 40 seconds, less than 35 seconds, less than 30 seconds, or less than 25 seconds.

The beverage may have a total dissolved solids amount of at least 0.5 %, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, 4%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5%, 4.6%, 4.7%, 4.8%, 4.9%, 5% or 5.1%, 5.2%, 5.3%, 5A%, 5.5%, 5.6%, 5.7%, 5.8%, 5.9%, 7%, 7.1%, 7.2%, 7.3%, 7.4%, 7.5%, 7.6%, 7.7%, 7.8%, 7.9%, 8%, 8.1%, 8.2%, 8.3%, 8.4%, 8.5%, 8.6%, 8.7%, 8.8%, 8.9%, or at least 9%.

The beverage may have a total dissolved solids amount of no more 10%, 8.9 %, 8.8 %, 8.7 %, 8.6 %, 8.5 %, 8.4 %, 8.3 %, 8.2 %, 8.1 %, 8 %, 7.9 %, 7.8 %, 7.7 %, 7.6 %, 7.5 %, 7.4 %, 7.3 %, 7.2 %, 7.1 %, or no more than7 %.

Preferably, the beverage may have an amount of total dissolved solids of 1.0 - -10.0%, 4.0 -10.0%, 4.0 %, 5.2 -10 %, 5.3 -10 %, 5.4 -10 go, 5.5 -10 %, 5.6 -10 %, 5.7 -10 %, 5.8 -10 %, 5.9 -10 %, 6 -10 %, 6.1 -10 %, 6.2 -10 %, 6.3 -10 %, 6.4 -10 %, 6.5 -10 %, 5 -10 %, 5.1 -9.9 go, 5.2 -9.8 %, 5.3 -9.7 %, 5.4 -9.6 %, 5.5 -9.5 %, 5.6 -9.4 %, 5.7 -9.3 %, 5.8 -9.2 %, 5.9 -9.1 %, 6 -9 %, 6.1 -8.9 %, 6.2 -8.8 %, 6.3 -8.7 %, 6.4 -8.6 %, or from 6.5 -8.5 %.

Such low residues have the advantage of low waste of beverage ingredient powder and reduced need for addition of excess beverage ingredient powder such that sufficient powder is transported into the beverage. They also have the advantage of more desirable beverages with more in cup solids resulting in better mouthfeel and taste.

Preferably, the beverage is a chocolate beverage.

According to a sixth aspect of the invention, there is provided a product produced according to the second aspect of the present invention for use in a beverage preparation machine.

Preferably, the beverage preparation machine is a coffee and/or chocolate beverage preparation machine.

According to a seventh aspect of the present invention, there is provided a process for manufacturing a product for preparing a chocolate beverage comprising the steps of: 10.0%, 1 -10.0%, 2 -10.0%, 2.5 -10.0%, 3.0 -10.0%, 3.5 -10, 4.5 -10%, 5.0 -10%, 5.5 -10%, 5 -10 %, 5.1 -10 a) spraying an aqueous liquid onto a dry mixture comprising a cocoa ingredient and sugar to wet the mixture; h) adding a cocoa ingredient and one or more beverage ingredient powders to the wetted mixture to attach the one or more beverage ingredients and sugar onto a surface of the cocoa ingredient; and c) drying the mixture formed in step b) to form a product comprising a cocoa ingredient having one or more beverage ingredient powders and sugar attached on a surface thereof.

The process may incorporate any of the features of the first aspect of the invention, but wherein the fibre-containing ingredient is limited to a cocoa ingredient.

According to an eighth aspect of the present invention, there is provided a product for preparing a chocolate beverage obtainable by the process according to the eighth aspect. of the invention.

The product may comprise any of the features of the second aspect of the invention, but wherein the fibre-containing ingredient is limited to a cocoa ingredient.

The further aspects of the present invention may incorporate any of the features of the other aspects of the invention described herein as desired or as appropriate.

Detailed Description of the Invention

In order that the invention may he more clearly understood one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which: Figure 1 shows a schematic of the process of the present invention.

Figure 1 illustrates a general process scheme of the present invention. A fibre containing ingredient and sugar are added to a granulator where they are subjected to dry mixing in a first phase. The mixture is then sprayed with aqueous liquid in a second phase to wet the mixture. One or more beverage ingredient powders are then added in a third phase and the resulting mixture is mixed further in a fourth phase to attach the beverage ingredient powders and sugar onto a surface of the fibre-containing ingredient. The mixture is then dried to form a product according to the second aspect of the invention.

Examples

The products of Examples 1 and 3 were prepared according to a process of the first aspect of the present invention and as shown in the process scheme of Figure 1.

Example 1

Sucrose in an amount of 20 wt.%, salt in an amount of 2 wt.% by weight of the mixture and granulated cocoa powder having a median particle size of 550 pm in an amount of 78 wt.% by weight of the mixture were placed inside a Lodige L5 granulator operating at a spray pressure of 5 bar and a tip speed of 2 m/s. Water was then sprayed onto the mixture during mixing in an amount of 13.3 wt.% by weight of the mixture. A dairy creamer was then added to the mixture in the granulator in an amount of 43.4wt.% and cocoa powder in amount of 2.4wt.% by weight of the resulting mixture. The resulting mixture was then mixed for a period of 5 minutes.

The spraying of the water and shear created by the mixing impeller of the granulator, resulted in the attachment of dairy creamer, salt, flavouring and sugar in a discontinuous covering across the surface of the granulated cocoa powder. The coated granulated cocoa was then dried using a Neuhaus Neotec LEB mini L dryer to form a product according to the second aspect of the invention. The drier had a temperature of 60°C and an airflow of 120Nm3/h.

The product of Example I had a median particle size of 544 p m, a bulk density of 682 g/1 and comprised cocoa powder in an amount of 40 wt.% by weight of the product creamer in an amount of 43.2 wt.% by weight of the product, sucrose in an amount of 9.4% by weight of the product and salt in an amount of 1.1 wt.% by weight of the product.

The product did not possess significant fines (1.29% fines <100um) and the cocoa powder had an attachment of creamer, salt, flavouring and sucrose across the surface of the cocoa powder.

g of the product of Example I was then packed into a Sensed filter pad of compostable paper without plastic insert and brewed using a Senseo Original beverage preparation machine and the double pad holder. The machine provides water heated to between 85 and 95 "C and a target drink volume of 120 ml. The product had a solids content of 7%.

The product showed improved solubility, creaminess, mouthfeel and sweetness when compared with a similar mixture of the ingredients without attachment on the surface of the cocoa ingredient. Additionally, the product demonstrated a reduced amount of leftover residue of wetted powder. Moreover, the product was able to successfully brew without the need for any additional inserts to improve solubility, thereby reducing waste and costs.

Reference Example 2

Sucrose in an amount of 9.4 wt.%, salt in an amount of 1.1 wt.%, dairy creamer in an amount of 43.2 wt.%, cocoa powder in an amount of 6.2 wt.%, and granulated cocoa powder with a median particle size of 550 gm in an amount of 40 wt. % were placed inside a Lodige L5 granulator operating at a spray pressure of 5 bar and a tip speed of 2 m/s. Water in an amount of 8wt.% was then sprayed onto the mixture during mixing. The resulting mixture was then mixed for a period of 5 minutes.

The spraying of the water and shear created by the mixing impeller of the granulator, resulted in the coating of dairy creamer, salt, flavouring and sugar across the surface of the granulated cocoa. The cocoa ingredient was then dried using a Neuhaus Neotec LFB mini L dryer to form a product of the second aspect of the invention. The drier had a temperature of 60°C and an airflow of 120Nthh.

The product of Reference Example 2 had a median particle size of 918 p m, a bulk density of 629 g/I and comprised cocoa powder in an amount of 42.5 wt.% by weight of the product and creamer in an amount of 26 wt.% by weight of the product, flavouring in an amount of 0.3 wt.% by weight of the product, sugar in an amount of 31wt.% by weight of the product and salt in an amount of 0.3 wt.% by weight of the product.

The product did not possess significant fines (0.27% fines <100um) and the cocoa powder was coated with a uniform layer of beverage ingredient powder, salt, flavouring and sugar.

g of the product of Reference Example 2 was then packed into a Senseo filter pad of compostable paper without plastic insert and brewed using a Senseo Original 30 beverage preparation machine and the double pad holder. The machine provides water heated to between 85 and 95 °C and a target drink volume of 120 ml. The product had a solids content of around 5.9%.

The product showed reduced solubility and appearance when compared with the product of Example 1. Use of the product also resulted in an increased amount of leftover residue of wetted powder.

Example 3

Sucrose in an amount of 20 wt.%, salt in an amount of 2 wt.% by weight of the mixture and ground cocoa shells having a median particle size of 575 pm in an amount of 78 wt.% by weight of the mixture were placed inside a Lodige L5 granulator operating at a spray pressure of 5 bar and a tip speed of 2 m/s. Water was then sprayed onto the mixture during mixing in an amount of 21.7 wt.% by weight of the mixture. A dairy creamer was then added to the mixture in the granulator in an amount of 41.2 wt.% and cocoa powder in amount of 2.3 wt.% by weight of the resulting mixture. The resulting mixture was then mixed for a period of 5 minutes.

The spraying of the water and shear created by the mixing impeller of the granulator, resulted in the attachment of dairy creamer, salt, flavouring and sugar across the surface of the cocoa shells. The attached cocoa shells were then dried using a Neuhaus Neotec LFB mini L dryer to form a product of the second aspect of the invention. The drier had a temperature of 60°C and an airflow of 120N m3/h.

The product of Example 3 had a median particle size of 625 pm, a bulk density of 710 The product also did not possess significant fines (0.04% fines <100um) and the cocoa shells had an attachment of beverage ingredient powder, salt, flavouring and sugar in a discontinuous covering across the surface of the cocoa shells.

g of the product of Example 3 was then packed into a Sensco filler pad of compostable paper without plastic insert and brewed using a Senseo Original beverage preparation machine and the double pad holder. The machine provides water heated to between 85 and 95 °C and a target drink volume of 120 ml. The product had a solids content of around 5.8%.

The product showed improved solubility, creaminess, mouth feel and sweetness 30 when compared with a similar mixture of the ingredients without attachment of the ingredients on the surface of the cocoa ingredient. Additionally, the product provided a brew with a reduced amount of leftover residue of wetted powder. Moreover, the product was able to successfully brew without the need for any additional inserts to improve solubility, thereby reducing waste and costs.

The one or more embodiments are described above by way of example only.

Many variations are possible without departing from the scope of protection afforded by the appended claims.

Claims (30)

1. CLAIMS1. A process for manufacturing a product for preparing a beverage comprising the steps of: a) spraying an aqueous liquid onto a dry mixture comprising a fibre-containing ingredient and sugar to wet the mixture; b) adding one or more beverage ingredient powders to the wetted mixture to attach the one or more beverage ingredients and sugar onto a surface of the fibre-containing ingredient; and c) drying the mixture formed in step b) to form a product comprising a fibre-containing ingredient having one or more beverage ingredient powders and sugar attached on a surface thereof.
2. 2. A process according to claim 1, wherein the fibre-containing ingredient is selected from the group consisting of sugarcane fibre, wheat, pea fibre, potato, oats, cocoa beans, cocoa (press) cake, cocoa mass, cocoa nibs, cocoa bean shells (also known as cocoa nib shells), cocoa pod husk (also called cocoa pod shells), ground cocoa bean shells (also known as ground cocoa nib shells), ground cocoa pod husk, cocoa powder, granulated cocoa powder and any combination
3. 3. A process according to claim 2, wherein the fibre-containing ingredient is a cocoa ingredient selected from the group consisting of a ground cocoa bean shells (also known as ground cocoa nib shells), ground cocoa pod husk granulated cocoa shell or granulated cocoa powder and any combination.
4. 4. A process according to any preceding claim, wherein the fibre-containing ingredient has a particle size of from 400 -750 pm.
5. 5. A process according to any preceding claim, wherein the sugar is selected from the group consisting of glucose, sucrose, fructose, galactose, lactose, molasses, maltose and combinations thereof.
6. 6. A process according to claim 1, wherein the one or more beverage ingredient powders are selected from the group consisting of instant coffee powder, a chocolate powder, a milk powder, dairy creamer, or a non-dairy creamer powder, and combinations thereof.
7. 7.
8. 8.
9. 9.
10. 10.
11. 11.A process according to any preceding claim, wherein the aqueous liquid is water or a sugar solution.A process according to any preceding claim, wherein the process further comprises the step of adding a flavouring, preferably wherein the flavouring is selected from the group consisting of chocolate (or cocoa), vanilla, salt, strawberry, cinnamon, mint, hazelnut, caramel, and combination thereof A process according to any preceding claim, wherein the step of spraying the aqueous liquid may comprise spraying an aqueous liquid in an amount of from 1-20wt.%, 5-20wt.%, 10-20wt.%, or 10-15vvt.% by weight of the product during step a).A process according to any preceding claim, wherein the step of adding one or more beverage ingredient powders may comprise adding one or more beverage ingredient powders in an amount of from 1-60wt.%. 1-55wt.%. 1-50wt.%, 1-45wt.%, 1-40wt.%, 1-35wt.%, 5-40wt.%, 10-40wt.%, 15-40wt.%, 2040wt.%, 25-40wt.(70, or 30-40w1.% by weight of the mixture formed in step b). A process according to any preceding claim, wherein the dry mixture comprises a fibre-containing ingredient in an amount of from 1-99wt.%, 1-95wt.%, 1-90wt.%, 1-85vv1.%, 1-80wt.%, 1-75wt.%, 1-70wt.%, 1-65wt.%, 10-65wt.%, 15-65wt.%, 20-65wt.%, 25-65wt.%, 30-65wt.%, 35-65wt.%, 40-65wt.%, or 45-55wt.% by weight of the dry mixture.
12. 12. A process according to any preceding claim, wherein the process further comprises the step of densifying the fibre-containing ingredient after and/or during step b).
13. 13. A process according to claim 12, wherein the step of densifying the fibre- containing ingredient may comprise increasing the density of the fibre-containing ingredient to at least 400 g/l.
14. 14. A process according to any preceding claim, wherein the process further comprises a step of filling a mixing device with the fibre-containing ingredient and sugar and wherein the step of filling the mixing device is before step a).
15. 15. A process according to claim 11. wherein the mixing device is a granulator.
16. 16. A product for preparing a beverage obtainable by a process according to any one of claims 1-15.
17. 17. A product according to claim 16, wherein the product comprises a fibre-containing ingredient in an amount of from 15-65wt.%, 20-65wt.%, 25- 65wt.%, 30-65wt.%, 30-60wt.%, 30-55wt.%, 30-50wt.%, or 35-45wt.% by weight of the product.
18. 18. A product according to any one of claims 16-17, wherein the product comprises one or more beverage ingredient powders in an amount of from 1-60wt.%, 1 -55wt.%, 10 -50wt.%, 15 -45wt.%, 20 -40wt.%, 25 -45wt.%, 25 -40 wt.% or 30 -40wt.% by weight of the product.
19. 19. A product according to any one of claims 16-18, wherein the product comprises a sugar in an amount of from 1-35wt.%, 1-35wt.%, 5-35wt.%, 10-35wt.%,15-35wt.%, 20-35wt.%, or 25-35wt.% by weight of the product.
20. 20. A product according to any one of claims 16-19, the product comprising a flavouring in an amount of from 0.1-1.0wt.%, 0.2-1.0wt.%, 0.3-1.0wt.%. 0.5- 1.0wt.%, or 0.6-1.0wt.% by weight of the product.
21. 21. A product according to any one of claim 16-20, wherein the one or more beverage ingredient powders and sugar discontinuously cover the surface of the fibre-containing ingredient.
22. 22. A product according to any one of claims 16-21, wherein the mean density of the product is between 400-750 g/l.
23. 23. A container comprising the product of any one of claims 16-22.
24. 24. A container according to claim 23, wherein the container is a beverage preparation machine insertable container.
25. 25. A method of preparing a container according to claim 23 comprising steps of: a) providing a product produced according to any one of claims 16-22; and b) adding the product to a container according to any one of claims 23-24.
26. 26. A method of preparing a beverage comprising the steps of; a) providing a product according to claims 16-22; transporting fluid through the product; and c) dissolving and/or suspending at least some of the product in the fluid such that the fluid comprises at least a portion of the product dissolved and/or suspended therein.
27. A method according to claim 26, wherein the volume of fluid transport in step b) is between 50m1 -350 ml; optionally wherein the fluid is transported at a pressure of at least 1 bar; and optionally wherein the time taken for steps b) to c) is less than 200 seconds, less than 100 seconds, less than 60 seconds or less than 25 seconds.
28. A product according to any one of claims 16-22, for use in a beverage preparation machine.
29. A process for manufacturing a product for preparing a chocolate beverage comprising the steps of: a) spraying an aqueous liquid onto a dry mixture comprising a cocoa ingredient and sugar to wet the mixture; adding a cocoa ingredient and one or more beverage ingredient powders to the wetted mixture to attach the one or more beverage ingredients and sugar onto a surface of the cocoa ingredient; and c) drying the mixture formed in step b) to form a product comprising a cocoa ingredient having one or more beverage ingredient powders and sugar attached on a surface thereof.
30. 30. A product for preparing a chocolate beverage obtainable by a process according to claim 29. 27. 28. 29.