Gasified coffee product and process

#1. Technical Field

#This invention relates to vegetable extracts, more specifically extracts of coffee and processes for producing such products. Coffee in the form of a high solids homogeneous melt is gasified, forced through an orifice and cooled to form a controlled light density coffee glass which when sized has the appearance of roasted and ground coffee, freeze-dried coffee or other useful appearances depending on the degree of gasification. The melt may be aromatized prior to formation of the desired shape. The product exiting the die may be stretched to control its final form. An object of this invention is to provide economical processes for shaping and preparing shelf-stable coffee products which have not suffered from heat damage and yet may be quickly reconstituted in hot water to yield coffee of excellent flavor and aroma. The process is particularly suitable for producing aromatized gasified coffee of controlled density and color which can be sized and dried to a stable condition without need for extensive freeze or spray drying. Such gasified soluble coffee glass can then be further treated, as by agglomeration, to form novel appearing products.

#2. Prior Art

#In accordance with the present invention a coffee glass product is prepared by forming a mixture of 88% to 97%, preferably from 91% solids to below 96% solids and 3 to 12%, preferably above 4% to 9%, water at a temperature of from 60.degree. to 130.degree. C. The mixture is then injected with gas, preferably inert gas, in a confined area, aromatized if desired, and forced through a restricted area or die at pressures of up to 2500 pounds per square inch. The mixture is then rapidly cooled by liquid nitrogen, cold air or by pulling the gasified melt by means of a traveling belt or roller to reduce the thickness of the shape produced and to allow rapid cooling whereupon the cooled material or glass is suitably reduced in size and dried to a stable moisture content. This glass may then be combined with other coffees.

#The coffee mixture can be prepared from coffee extract obtained by normal percolation by subjecting the extract to falling film evaporators or other suitable devices, to obtain a solids content of at least 88% and more preferably 91% or more. The solids content is adjusted to form a mixture which will form a super-cooled gasified coffee glass upon cooling. The coffee mixture can also be obtained by mixing dried coffee solids, spray-dried, freeze-dried or otherwise, with sufficient water to produce a moisture content up to 12%, more preferably between above 4% and 9%.

#With sufficient mixing there is produced a homogeneous material which is similar to that obtained by concentration of coffee extract. The coffee mixture can also be prepared by adding a small amount of dry soluble coffee to concentrated coffee extract. In all cases the coffee solids obtained should have a glass transition temperature of between 30.degree. C. to about 80.degree. C.