Methods and systems for forming concentrated consumable extracts

Abstract

Typical known methods for producing large quantities of concentrated extracts from solid raw materials such as ground, roasted coffee are not ideally suited to producing high quality coffee extracts that are rich in flavor and fragrance, and which maintain the varietal characteristics of the roasted coffee from which they are produced. The current invention provides filtration methods e.g. reverse osmosis or nanofiltration for producing such high quality concentrated extracts from more dilute extracts via solvent removal. The invention provides methods that have sufficient flexibility and scalability to be used for a wide variety of applications, including for producing industrial—scale quantities of extracts for the food and beverage industry. The invention provides methods and apparatus that can produce highly concentrated, “gourmet quality” extracts for use as flavoring agents, beverage concentrates, and fragrances. The solvent—reduced, concentrated extracts produced according to the inventive solvent removal methods can be advantageously used for applications where high quality coffee extracts, with a high concentration of soluble coffee solids, for example of at least 6 wt. %-40 wt. %, and a high level of retention of varietal flavor and fragrance characteristics are desired.

1 - 24 . (canceled) 
     
     
         25 . An aqueous coffee extract obtained by extraction of a quantity of roasted coffee, said quantity including at least one chosen variety of roasted coffee, said extract having at least about 15% wt. dissolved coffee solids, and retaining an effective amount of the varietal flavor and fragrance components characterizing said at least one chosen variety of roasted coffee from other varieties of roasted coffee. 
     
     
         26 . The aqueous coffee extract as recited in  claim 25 , wherein the extract contains at least about 20% wt. dissolved coffee solids. 
     
     
         27 . The aqueous coffee extract as recited in  claim 26 , wherein the extract contains at least about 25% wt. dissolved coffee solids. 
     
     
         28 . The aqueous coffee extract as recited in  claim 27 , wherein the extract contains at least about 30% wt. dissolved coffee solids. 
     
     
         29 . The aqueous coffee extract as recited in  claim 28 , wherein the extract contains at least about 40% wt. dissolved coffee solids. 
     
     
         30 . A method for producing a blended coffee extract, the method comprising:
 a. extracting a quantity of roasted coffee with a quantity of aqueous solvent to form a first-pass coffee extract having a concentration of dissolved coffee solids therein of a first value;   b. extracting the same quantity of roasted coffee previously extracted in step (a) with an additional quantity of aqueous solvent to form a second-pass coffee extract having a concentration of dissolved coffee solids therein of a second value less than first value;   c. increasing the concentration of dissolved coffee solids in the second-pass coffee extract by removing a quantity of aqueous solvent therefrom; and   d. mixing a quantity of the first-pass extract with a quantity of the second-pass extract concentrated in step (c) to form a blended extract.   
     
     
         31 . The method as recited in  claim 30 , wherein in step (c) the concentration of dissolved coffee solids in the second-pass coffee extract is increased by removing by filtration a quantity of aqueous solvent therefrom. 
     
     
         32 . The method as recited in  claim 30 , wherein in step (d) the quantity of the first-pass extract is greater than the quantity of the second-pass concentrated in step (c). 
     
     
         33 . The method as recited in  claim 30 , wherein in step (d) the quantity of the first-pass extract is less than the quantity of the second-pass concentrated in step (c). 
     
     
         34 . The method as recited in  claim 30 , wherein in step (d) the quantity of the first-pass extract and the quantity of the second-pass concentrated in step (c) are essentially equal. 
     
     
         35 . The method as recited in  claim 30 , wherein in step (c) the concentration of dissolved coffee solids in the second-pass extract is increased to about said first value. 
     
     
         36 . The method as recited in  claim 35 , wherein in step (d) the quantity of the first-pass extract and the quantity of the second-pass concentrated in step (c) are essentially equal. 
     
     
         37 . A blended coffee extract produced according to the method recited in  claim 30 . 
     
     
         38 . The method as recited in  claim 30 , wherein the blended extract has a concentration of dissolved coffee solids of at least about 6% wt. 
     
     
         39 . A blended coffee extract produced according to the method recited in  claim 38 . 
     
     
         40 . The method as recited in  claim 38 , further comprising after step (d):
 e. diluting the blended extract with aqueous solvent so that the concentration of dissolved coffee solids is between about 1% wt. and about 4% wt.   
     
     
         41 . (canceled)