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Description  |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an improvement in a batch mixing
process for a beverage syrup which results in a requirement for
significantly lesser quantities of water to be used in the syrup making
process, primarily by reducing the amount of rinse water required therein.
In greater detail, the present invention does not employ rinse water, as
in the prior art, to rinse between the separate premixing steps for the
separate components of the beverage syrup.
2. Discussion of the Prior Art
A currently employed batch making premix process for the production of many
contemporary soft drink beverages utilizes a preliminary process for
making a beverage syrup, which is followed by a mixing of the syrup with
water (commonly called "throwing the beverage"), carbonating this mixture,
and then filling containers therewith.
In the preliminary process of making the syrup (containing flavor, sugar,
water, various salt solid components, juice, and other liquid components),
concentrated salts are typically predissolved in water utilizing a small
predissolving or premixing vessel. These solutions are, in turn, added to
the remaining ingredients in a larger syrup mixing tank.
The recipe for syrup utilized in many contemporary soft drink beverages
incorporates therein a number of various salt components which are mixed
together to form the beverage syrup. In actual practice, the salt
components, and some liquid components as well, cannot be mixed together
all at once because of possible gross negative chemical interactions
therebetween when the salt components are present simultaneously in highly
concentrated forms. Accordingly, the present state of the art dilutes one
salt component at a time with water in the premixing (or predissolving)
tank, and then pumps the diluted component from the premixing tank through
a feed line to the already partially prepared syrup mixture in a larger
syrup tank. The premixing tank and its associated feed line are then
rinsed with water prior to the next step of diluting the next salt
component in the premixing tank, and the rinse water is added to the
already partially prepared syrup mixture in the larger syrup tank, and
etc. In such a syrup making process and arrangement, the premixing tank
and its feed line are rinsed with water a number of different times, which
results in an overall usage of a large quantity of rinse water in the
production of a given quantity of finished beverage product.
As an example of such gross chemical negative interactions, in soft drink
recipes containing both potassium benzoate and citric acid, if those two
components are present simultaneously in highly concentrated forms, the
potassium benzoate is converted into benzoic acid crystals which settle
out of the solution. Various other salt components which are utilized in
contemporary syrup recipes include sodium benzoate, potassium citrate,
sodium citrate, potassium sorbate, sodium sorbate, mallic acid, Aspartame,
various gums such as pectin, erythorbic acid, caffeine, ascorbic acid,
sorbic acid, flavorants, calcium salts, and sodium chloride. In general,
these ingredients are primarily solids which are dissolved and diluted
with water in the premixing or predissolving tank, and are then pumped in
diluted form through the feed line into the already partially prepared
syrup recipe in the syrup tank. Additional liquid ingredients include food
grade acids such as phosphoric and hydrochloric acids, juices, flavorants
and antifoaming agents.
Accordingly, in syrup formulas using a high number, such as five or six,
such salt components therein, the premixing tank and the feed line are
rinsed and flushed with water after each such component is diluted, such
that the next concentrated component does not interreact with the previous
component, even in a diluted form thereof. Thus, this often involves six
or seven different rinsing and flushing operations after each salt
component is predissolved, involving the additions of large quantities of
rinse water to the syrup mixture being prepared.
Bulatkin U.S. Pat. No. 2,988,450 discloses a premix process, and contains
therein a discussion of rinsing problems which arise when changing
flavors. Kalko et al U.S. Pat. No. 3,938,537 discloses a premix process
having both a premixing container and mixing containers, and also
incorporates therein a discussion of cleaning (rinsing) steps involved
therein. Wieland et al U.S. Pat. No. 4,599,239 incorporates therein
several discussions of premixing steps and the considerations thereof. In
summary, the prior art cited hereinabove discusses only generally the
problems associated with rinsing of predissolved or premixing equipment,
and does not disclose the syrup batching loop process of the present
invention, or the significant advantages thereof.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a
batch mixing process and arrangement for the preparation of a beverage
syrup which results in a requirement for significantly lesser quantities
of water in the syrup mixing process, primarily by reducing the amount of
rinse water required to rinse between the mixing of the separate
components of the beverage syrup.
Another object of the present invention is to provide a syrup batching loop
process and arrangement which allows a bottler to throw (i.e. mix the
beverage syrup with water) the beverage at a higher ratio (with more
water), which is a more cost efficient operation, if available, since the
syrup making portion of the overall operation is usually the most time
consuming aspect of the overall beverage preparation process.
The present invention provides three very significant benefits.
1. It allows small batches to be made with formulas that do not have much
"free water" therein, primarily because separate additions of water are
not required for rinsing. Several formulas, especially juice containing
beverages, do not have much available water in the syrup formula for
rinsing between salt dissolution steps. The majority of water is
introduced with the sugar and juice. As such, smaller units can only be
made if the beverage is thrown at a lower ratio (e.g. 1+4 instead of
1+5--wherein 1 refers to 1 part syrup and n refers to n parts water). This
alternative requires more syrup to be made per unit of finished carbonated
soft drink. Syrup making is a time consuming step, and accordingly
bottlers always prefer to throw the beverage at the highest ratio
possible.
2. It also allows larger batches to be thrown at higher ratios than are
currently employed. Less water is required in the syrup formula, and thus
the beverage can be thrown at a higher ratio.
3. Another benefit is that higher Brix products can be made at normal
throws (e.g. 1+5 is normal).
A further object of the subject invention is the provision of a syrup
batching loop employing a main syrup tank and a subsidiary premixing tank
for premixing selected components of the beverage syrup with a quantity of
water to dilute the premixed component. Similar to the prior art, a feed
line extends from the premixing tank to the syrup tank such that each
diluted premixed component can be pumped therethrough from the premixing
tank to the main syrup tank. A major feature of the present invention is
the utilization of a recycle line extending from the syrup mixing tank
back to the premixing tank, which allows recycling of the syrup mixture
from the syrup tank to the premixing tank for rinsing of the premix
equipment between the individual mixing steps of the overall syrup making
process.
Pursuant to the teachings of the present invention, preferably while, but
possible after, the premixing tank is emptied of the diluted component
into the syrup tank to form a partially completed beverage syrup therein,
the premixing tank and the lines associated therewith are rinsed with the
partially completed beverage syrup from the syrup tank, rather than with
added rinse water as in the prior art. The premixing and rinsing steps are
repeated for each additional component of the beverage syrup mixture which
must be premixed in that manner to provide a diluted component, such that
the rinse water normally required to rinse the premixing vessel and the
lines associated therewith between each different premixing step is
eliminated. The teachings of the present invention relative to the
premixing and rinsing operations are typically performed upon soft drink
recipes having a plurality of separate and different salt components
therein, such as five or more separate and different salt components, such
that a substantial quantity of additional rinse water can be eliminated
from the syrup mixture.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects and advantages of the present invention for a syrup
batching loop may be more readily understood by one skilled in the art
with reference being had to the following detailed description of a
preferred embodiment thereof, taken in conjunction with the accompanying
drawings wherein like elements are designated by identical reference
numerals throughout the several views, and in which:
FIG. 1 is an exemplary embodiment of a prior art batch syrup mixing
arrangement constructed pursuant to the teachings of the prior art; and
FIG. 2 illustrates an exemplary embodiment of a syrup batching loop process
and arrangement constructed and operated pursuant to the teachings of the
present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exemplary embodiment of a prior art batch syrup mixing
arrangement employing a main syrup tank 10, which is typically a one to
ten thousand gallon container, and a subsidiary premixing tank 12, which
is typically a fifty to seven hundred and fifty (usually one hundred and
fifty) gallon container. The premixing tank 12 is provided for premixing
selected components of the beverage syrup with a quantity of water to
dilute the premixed component, primarily to prevent negative chemical
interactions that can occur between undiluted components thereof. A feed
line 14 extends from the premixing tank 12 to the syrup tank 10 such that
after dilution, the diluted premixed component can be pumped, such as by a
conventional pump 16, from the premixing tank 12 through the feed line 14
to the main syrup tank 10. After completion of preparation of the syrup, a
valve 18 to a syrup output line 20 is opened to allow the completed syrup
to drain and flow to a filler for the throwing of the beverage.
The recipe for syrup utilized in many contemporary soft drink beverages
incorporates therein a number of various salt components which are mixed
together to form the beverage syrup. The present state of the art dilutes
one salt component at a time in the premixing tank 12, and then adds the
diluted component from the premixing tank 12 to the already partially
prepared syrup mixture in the larger syrup tank 10. The premixing tank 12
and its feed output line 14 are then rinsed with water and the rinse water
is then pumped into the syrup tank 10 prior to the next step of diluting
the next salt component in the premixing tank, which is then added to the
already partially prepared syrup mixture in the larger syrup tank, the
rinsing step is repeated, and etc. In such a syrup making process and
arrangement, the premixing tank 12 and its feed line are rinsed with water
a number of different times, which results in the overall addition of a
large quantity of rinse water to the syrup mixture being prepared.
FIG. 2 illustrates an exemplary embodiment of a syrup batching loop process
and arrangement constructed and operated pursuant to the teachings of the
present invention. The syrup batching loop process and arrangement of the
present invention also uses a finished syrup tank 10, a mixing tank 12,
and a feed line 14. A key difference between the new process and the
existing operation is that a recycle or return line 22 extends from the
syrup tank back to the predissolving tank, and is provided to allow a
recycling of the syrup mixture from the syrup tank 10 to the premixing
tank 12 for rinsing of the premixing equipment between the individual
mixing steps of the overall syrup making process.
Pursuant to the teachings of the present invention, while or after the
premixing tank 12 is emptied of a diluted component into the syrup tank to
form a partially completed beverage syrup therein, the premixing tank 12
and the feed line 14 are rinsed with the partially completed beverage
syrup from the syrup tank, rather than with added rinse water. The
premixing and rinsing steps are then repeated for each additional
component of the beverage syrup mixture which must be premixed in that
manner to provide a diluted component, such that the rinse water normally
required to rinse the premixing vessel and the output line after each
different premixing step is no longer required.
Referring specifically to FIG. 2, in addition to the recycle line 22, the
arrangement also includes a valve 24 to allow the addition of rinse water,
which is still required after the last premixing step. A valve 26 is
provided to allow the addition of liquid ingredients to be pumped through
the recycle line 22 and the feed line 14 into the syrup tank 10. A three
way valve 28 allows the mixture to flow to either the recycle line during
preparation of the syrup or to the output line 20 after preparation of the
completed syrup. A valve 30 is provided in the recycle line 22 just before
a T fixture 32, and a valve 34 is provided beneath the premixing tank 12
and above the T fixture 32. A three way valve 36 is also provided in the
feed line 14 at the output of the pump 16, and can direct the output of
the pump either to the feed line 14 or to a rinse line 38, which may or
may not include a flexible rinse hose and spray nozzle as explained
hereinbelow. Many alternative piping and valving arrangements are possible
and contemplated within the teachings of the present invention.
By way of further explanation, assume that a syrup making process is in
progress, that the syrup tank 10 is partially filled with water and sugar
as required by the particular syrup recipe, and that a first salt
ingredient has been premixed in the premixing tank 12. At this time,
valves 24 and 26 are closed, valve 18 is open, valve 28 is positioned to
allow flow through the recycle line 22, valve 30 is open, valve 34 is
closed, and valve 36 is positioned to allow flow through the feed line 14.
With these valve positions, pump 16 is continuously cycling and mixing the
syrup and water solution through the recycle and feed lines 22, 14. Valve
34 is then opened to allow the diluted salt solution from premixing tank
12 to flow into and gradually mix with the sugar and water solution being
pumped through the recycle and feed lines 22, 14. After premixing tank 12
is empty, it is rinsed by changing the position of three way valve 36 to
allow flow into the rinsing line 38.
It should be recognized that in various premixing facilities now in
existence, such in different bottling plants, the arrangements of the
particular syrup tank 10 and premixing tank 12 can be quite diverse. Some
premixing tanks 12 are open on top and some have removable covers, such
that a flexible hose can be used to spray down the interior of the
premixing tank during rinsing thereof. Such an arrangement with a separate
flexible rinse hose can present sanitation problems, however, as when the
hose is laid down, and are not preferred. An alternative arrangement
provides a return line 40 back to the premixing container such that when
valve 36 is repositioned during a rinsing operation, the partially
prepared syrup formula which is used for the rinsing operation simply
fills the predissolving tank for rinsing thereof, after which valve 36 is
repositioned to allow flow through the feed line 14 again, and valve 34 is
opened to allow the rinsing solution to flow therefrom to the pump 16.
After the premixing tank 12 is empty, the valve 34 is then closed, and the
premixing tank 12 is then ready to receive the next ingredient to be
premixed therein.
After all ingredients have been added to the syrup formula, a final rinsing
step of the premixing equipment is carried out with rinse water by closing
valve 18 and opening valve 24 to allow a final line rinsing with rinsing
water.
The valve 26 is provided to allow some liquid ingredients to the syrup
recipe to be added directly to the partially prepared syrup mixture as it
is being pumped by pump 16 through the recycle and feed lines 22, 14.
The teachings of the present invention relative to the premixing and
rinsing operations are typically performed upon soft drink recipes having
a plurality of separate and different salt components therein, which may
be as high as five or more separate and different salt components, such
that the savings in required rinse water can be considerable.
A typical example of a juice containing product thrown at 1+5 is listed
below.
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Current Prior Art
Syrup Batching
Process (FIG. 1)
Loop (FIG. 2)
(Gallons) (Gallon)
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Available Water in Syrup
Formula @ (1 + 5) Thow
27 27
Water Required for
Dissolving Salts
10 10
Water Required for
Rinsing Between
Ingredients 50 0
Water Required for
Rinsing Containers
2 2
Water Required for
Initial Syrup Charging
7 7
Water Required for Final
Line Rinsing 20 8
Net Water* (62) 27
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*Negative value for net water indicates that this syrup is impossible to
make when using the indicated process.
The present invention allows small batches of syrup to be made with
formulas that do not have much free water in them, primarily because
separate additions of water are not required for rinsing. Several
formulas, especially juice containing beverages, do not have much
available water in the syrup formula for rinsing between the salt
dissolution steps. The majority of water is introduced with the sugar and
juice. As such, smaller units can only be made if the beverage is thrown
at a lower ratio (e.g. 1+4 instead of 1+5). This alternative requires more
syrup to be made per unit of finished carbonated soft drink. Syrup making
is a time consuming step, and accordingly bottlers always prefer, for
economic reasons, to throw the beverage at the highest ratio possible.
Moreover, the present invention also allows larger batches to be thrown at
higher ratios than are currently employed. Less water is required in the
syrup formula, and thus the beverage can be thrown at a higher ratio.
While a preferred embodiment and several variations of the present
invention for a syrup batching loop are described in detail herein, it
should be apparent that the disclosure and teachings of the present
invention will suggest many alternative designs to those skilled in the
art.
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