Process for the production of a container for the preparation of a beverage in a beverage preparation device, sealing station for carrying out a sealing step of said process, and a container obtained by said process

A process for producing a container for preparing a beverage in a beverage preparation device, the process comprising the steps of:

• a. providing an injection wall of the container comprising a paper layer, the injection wall comprising:
• a peripheral sealing edge and an inner portion capable of being punctured by an injection member of the beverage preparation device for circulating water under pressure inside the container;
• b. providing a beverage delivery wall of the container comprising a paper layer, the beverage delivery wall comprising:
• a peripheral sealing edge and an inner portion capable of being opened by an opening member of the beverage preparation device when the pressure inside the container presses the inner portion against the opening member to let the beverage flow out, wherein at least one of the inner portions of the injection wall and the inner portion of the beverage delivery wall has a cup shape;
• c. placing a compacted body of beverage ingredient in the inner portion of the injection wall or the inner portion of the beverage delivery wall;
• d. placing the injection and delivery walls one above the other such that the sealing edges of the injection and delivery walls are superimposed, in order to form a preliminary container chamber containing the compacted body and comprising a preliminary headspace not filled by the compacted body;
• e. providing a sealing station comprising:
• first and second housing elements forming a sealing chamber for housing the inner portions of the injection wall and the inner portion of the beverage delivery walls, wherein the first and second housing elements are configured for being moved towards each other for sealing the peripheral sealing edge of the injection wall and the peripheral sealing edge of the beverage delivery wall, and wherein surfaces of the sealing chamber are in contact with external surfaces of the inner portions of the injection wall and the inner portion of the beverage delivery wall;
• f. pressing the first and second housing elements against the inner portion of the injection wall and the inner portion of the beverage delivery wall so as to form a final container chamber having a headspace reduced at least by 10% with respect to the preliminary headspace, and so that in the container thus obtained, at least 70% of an external surface of the compacted body of beverage ingredient is in contact with the injection wall and the beverage delivery wall, wherein the inner portion of the injection wall and the inner portion of the beverage delivery wall are at least partially pressed by the first and second housing elements until a distance between first opposing portions of two inner surfaces of the first and second housing elements is at least 0.1% lower than a final thickness of corresponding first opposing portions of a finished container;
• and
• g. sealing together the sealing edge of the injection wall and the sealing edge of the beverage delivery wall, while the inner portions of the injection wall and the inner portion of the beverage delivery wall are still pressed.