The challenge of keeping cold brew coffee ambient & stable
According to the National Coffee Association’s (NCA) fall 2024 National Coffee Data Trends report, cold brew coffee was the most popular non-espresso-based beverage. The report also reveals that the consumption of cold brew in the US alone has increased by 300% over the past seven years.
While coffee shops have been making their own cold brew for years, this increased demand has led to several ready-to-drink options becoming available. That said, the lack of sterilising temperatures during preparation can make it challenging to create great-tasting shelf-stable cold brew coffee.
To avoid microbiological contamination and deterioration in quality, cold brew coffee should be freshly prepared – but what does that mean for its shelf life?
To learn more about creating risk-free cold brew coffee, we looked at some answers from industry cold brew experts.
Cold brew coffee and food safety: What are the concerns?
According to a recent study, cold brew is one of the few coffee beverages that contains microbiological food safety hazards. The roasting process and hot brewing usually minimise risk, but the long brewing time of cold brew can facilitate microbiological activity.
The lack of acidity in cold brew can lead to serious issues if proper food safety practices aren’t in place. Researchers at the University of Georgia’s Center for Food Safety found that common pathogens in food-borne illnesses can survive in cold brew coffee for between nine and 12 days.
In an article about the study, UGA graduate research assistant Angela Parra was quoted saying “during my studies, at no point has the bacteria grown in cold brew. However, the pathogens have all survived within the coffee”.
That said, Angela noted that bacteria will not grow naturally in cold brew if it has not been added through contamination during the production process.
Randy Anderson is the Vice President of Product Strategy at Cold Percolation, Inc., and has worked with cold brew for over a decade. He notes that in-house cold brew production can be unhygienic.
“The fact that people leave cold brew to steep for up to 24 hours outside of refrigeration is by itself a violation of food safety laws in many parts of the US,” he stated in an article for Perfect Daily Grind.
However, he also points out that several innovative cold brew systems are helping to address issues of contamination and hygiene. Furthermore, many of these alternative brewing methods can produce cold brew in under an hour, further reducing the risk of contamination.
How is cold brew coffee packaging sterilised?
Hardtank offers innovative cold coffee solutions that help businesses create cold brew in half the time. According to an article on the brand’s website, pasteurisation is the most crucial phase for extending the shelf-life of RTD cold brew.
The majority of shelf-stable products are heat-treated to stop microbial growth and help keep beverages safe for non-refrigerated storage and transit. The most common methods used include:
Ultra-high-temperature (UHT) pasteurisation and aseptic filling: This process heats the liquid for a brief period to achieve sterilisation. This rapid heating process effectively eliminates microbial activity in the liquid. Cold brew that undergoes this process is often packaged in bag-in-box options, cartons, or flexible pouches to ensure the product remains free from contaminants.
High-temperature short time (HTST) sterilisation: This is a common process for those offering canned cold brew. The liquid is heated to 72ºC (161ºF) for 15 seconds. Manufacturers then hot-fill sterilised cans before placing them in a “retort”. This flushes the packaged product with steam for up to 15 minutes.
Cold chain storage can be expensive as it requires temperature-controlled warehouses and transportation. While this removes the requirement for pasteurisation post-sealing, it means that the product must be kept at consistently low temperatures throughout production and distribution, as well as while on display.
Pasteurisation exposes the sealed cold brew can to high temperatures, allowing for ambient storage, transport, and display.
How can brands package RTD cold brew to extend shelf-life?
As the popularity of cold brew grows, brands are finding innovative ways to package it to capture consumer attention. Some of the most common forms of cold brew coffee packaging include:
- BPA-free plastic bottles: The durability of BPA-free plastic cold brew bottles also ensures the contents inside remain protected from external factors.
- Bag-in-box (BiB) solutions: Combine aseptic packaging with a sturdy box exterior to protect the product and prevent exposure to sunlight.
- Aluminium cans: These are highly favoured for their convenience and aesthetic appeal.
- Cartons: The multi-layer construction ensures coffee remains fresh.
- Flexible pouches: Made from lightweight and durable materials, these are ideal solutions for transporting and storage.
Krzysztof Barabosz is one of the inventors of Hardtank. He explains that packaging such as cold brew pouches can help extend shelf life through several key mechanisms.
“The pouches are designed with materials that create a protective barrier against oxygen, light, and moisture,” he says. “This sealed packaging ensures that external elements do not degrade the quality of the cold brew over time, maintaining its freshness. Oxygen is a significant factor that can lead to the oxidation of coffee, resulting in changes in flavour and aroma.”
He adds that the actual shelf-life of cold brew coffee can vary depending on storage conditions. “The shelf-life duration will also vary depending on the presence of additives or preservatives,” he says.
In conclusion, food safety laws vary worldwide. Therefore, cold brew brands must understand their local and national regulations.
At Cold Brew Pak, we offer a variety of cold brew coffee packaging that is designed to protect the smooth and mellow flavours of your product until it reaches consumers. Our packaging line is suitable for common sterilisation processes and can be fully customised to suit your brand.
Reach out to our team for more information.
