Apparatus for making an instant beverage container with product therein

A system for packaging an instant beverage material in a beverage container having a bottom with a bottom diameter, the combination comprising:

• a filter disk having a first portion and an outer diameter;
• an insert disk having a diameter which is slightly greater than the bottom diameter of the beverage container, whereby the insert disk provides a friction fit wedging the insert disk inside the beverage container adjacent the bottom of the beverage container;
• a mandrel having a flange and an outer surface diameter;
• a forming die slideably mounted on the mandrel and having (a) a chamfered outer surface adapted to fit into the beverage container, (b) an inner stepped portion configured to engage the flange of the mandrel and to receive the filter disk and insert disk, (c) an inner surface diameter slightly larger than the outer surface diameter of the mandrel, and (d) an outer surface diameter smaller than the outer diameter of the filter disk;
• means for biasing the forming die in a first position relative to the mandrel and releasing the forming die to a second position relative to the mandrel, the biasing means attached to the mandrel;
• and
• a funnel press having a funnel portion and a press portion, the press portion mating with the mandrel and forming die to draw the first portion of the filter disk into the mandrel to simultaneously form a pocket in and crimp the filter disk which is subsequently loaded with the instant beverage material using the funnel portion;
• the insert disk adapted to be placed over the instant beverage material to secure the instant beverage material within the pocket formed in the filter disk, and the mandrel and forming die interact to fold a portion of the filter disk over the insert disk and insert the filter disk, insert disk, and instant beverage material securely into the bottom of the beverage container.