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How to seal recyclable plastic cold brew bottles

As the cold brew coffee trend continues to gain momentum, brands are beginning to master the art of creating packaging that blends precision and creativity. And, as competition in the market rises, standing out has become imperative. That said, aesthetics are not the only factor to consider when packaging cold brew coffee. 

While the look of your packaging is incredibly important, its overall functionality and how it affects the consumer experience is equally essential. When investing in plastic cold brew bottles, for instance, considerations of safety and quality are an absolute necessity. These safety and quality control processes are critical to upholding your brand’s reputation for producing high-quality products. 

Each bottle of cold brew coffee should undergo a thorough inspection, ensuring a flawlessly sealed product that preserves the flavour integrity of the beverage.

But how can you keep up with consumer demand while protecting the inherent characteristics of your cold brew? 

I spoke to Erene Henninger from Project Seed Coffee, a cold brew coffee home delivery company based in Virginia, to learn more. 

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Investing in cold brew bottles: Discover the benefits

Brands have several options when it comes to packaging cold brew coffee. However, one of the most common is recyclable plastic bottles. Beyond the obvious environmental benefits of opting for plastics that are free of Bisphenol A (BPA), which meet the current consumer expectation for sustainability, cold brew bottles provide many practical advantages in terms of shipping and consumer convenience. 

The motto for Project Seed Coffee explains everything about the brand: “modern-day milkman but with cold brew, and a woman.” The brand’s consumer base spans the entire US, offering customers refreshing, ready-to-drink (RTD) cold brew. Owner Erene has experienced the benefits of offering convenient, on-the-go options for consumers firsthand. 

“People want convenience and ready-to-go products,” she says, reflecting on the current consumer demands. “The pre-bottled cold brew allows that flexibility and also extends the shelf life [of the product].” 

Notably, the global ready-to-drink (RTD) coffee market is projected to reach $42.4 billion by 2027. This surge in demand stems from consumers between the ages of 18 and 39—cold brew coffee’s main demographic. The growth can also be attributed to this generation’s shift away from carbonated soft drinks, coupled with their increasingly fast-paced lifestyles. 

“All of our cold brew flavours (32 and counting) have a shelf life of 2 weeks,” Erene explains. “It can honestly stay longer, but as coffee ages, [acidic and bitter flavours] start to emerge.” BPA-free plastic bottles for cold brew have the ability to extend shelf life and ensure freshness and quality for customers. 

Sealing recyclable plastic cold brew bottles

With a constant need for innovation to remain competitive in the growing market, brands must offer a diverse range of flavours. Cold brew bottles provide a portable, on-the-go solution for coffee enthusiasts seeking variety and convenience in their beverage choices. That said, the importance of proper sealing techniques cannot be overstated.

Sealing plastic cold brew bottles effectively requires attention to detail and adherence to specific techniques to ensure product freshness and integrity. The process typically begins with the careful inspection of each bottle to identify any imperfections or defects that could compromise the seal.

At Project Seed Coffee, Erene assures customers that they can trust every bottle, which contains not just a beverage but also a testament to craftsmanship and dedication to excellence.

“We ensure that each and every bottle is sealed properly by laying them flat on a towel to check for leaks.” Erene explains. “It is important to ensure that each bottle is sealed correctly, as in our initial packaging, we’ve had leaks, which became a learning experience.”

Once the bottles pass quality control, a crucial step in the process, they can be filled. Tamper-evident caps, such as the 38mmDBJ favoured by Project Seed Coffee, are applied to each bottle to ensure a secure and leak-proof seal. These caps play a crucial role in safeguarding the contents of the bottle and providing visual assurance to consumers that the product remains untouched until opened. 

Brands may also invest in specialised equipment to aid in the sealing process, such as capping machines. Additionally, a manual inspection of each sealed bottle should be conducted to verify the integrity of the seal and address any issues before shipment. 

Overall, sealing cold brew bottles requires a combination of precision, attention to detail, and quality control measures to deliver a product that meets the highest standards of safety and quality.

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Why consider BPA-free plastic cold brew bottles?

In addition to ensuring sound sealing techniques, material choice and health and safety implications must be considered. BPA is a chemical compound found in many single-use plastics, and in recent years, research showing health hazards has raised concerns among consumers globally. Brands like Project Seed Coffee recognise the importance of prioritising BPA-free options to mitigate these risks and assure consumers of their commitment to safety.

The durability of BPA-free plastic cold brew bottles also ensures the contents inside remain protected from external factors. Designed to withstand the transportation and handling processes, these bottles safeguard the product’s integrity while enhancing its shelf presence.

Beyond this, the reusability of these cold brew bottles aligns with the growing expectations of eco-conscious consumers. Recyclable, BPA-free plastic bottles offer a sustainable alternative to single-use packaging, as they can be reused multiple times and then easily recycled. 

Research surveys found that 78% of consumers admit that a sustainable lifestyle is essential to them. Therefore, it’s imperative for brands to align product and packaging materials with these modern expectations. Investing in BPA-free plastic bottles made from recyclable polyethylene terephthalate (PET) ensures you’re offering consumers a convenient form of eco-friendly packaging that is easy to dispose of.

Ultimately, the choice depends on factors such as budget, branding objectives, and desired aesthetics. Regardless of the method chosen, investing in BPA-free cold-brew coffee bottles ensures both quality and peace of mind for consumers.

At Cold Brew Pak, we offer sleek, square-shaped bottles that are meticulously crafted from high-quality, BPA-free plastic to ensure durability and a modern aesthetic. This unique design not only maximise shelf space efficiency but also provides a secure grip, making them perfect for on-the-go enjoyment.

Our BPA-free plastic bottles for cold brew coffee are available in clear PET, biodegradable polylactic acid (PLA), and natural high density polyethylene (HDPE).

Images courtesy of Project Seed Coffee

Contact us today. 

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About the author

Holly Szakal is a Melbourne-based copy and content writer and is deeply immersed in her city's vibrant specialty coffee culture. She infuses the rich aromas of the specialty coffee scene by delivering compelling narratives on the industry's current events.