Custom cold brew boxes – which coffee processing method should you use?

Zoe Stanley-Foreman

December 16, 2024 |

As the cold brew market becomes more competitive, roasters must carefully select the right coffee for their custom cold brew box. This is crucial to meeting modern consumers’ high expectations. Choosing the right coffee – and the right processing method for that coffee – plays a key role.

Cold brew has become a permanent fixture in specialty coffee, with the global market set to grow by more than half a billion dollars in the next few years. Younger coffee drinkers continue to fuel this growth, driven by customisation and convenience across the board.

I spoke to Ruben Dario Sorto, Director at Fortune Mountain Coffee in Honduras and BioFortune Group, and Lauren Pfeiffer, VP of Brand and Customer Experience at BKON, to learn which processing methods and packaging best suit cold brew. Read on to hear their insights.

Unpacking common coffee processing methods

Coffee beans come from the fruit of the coffee plant, known as coffee cherries. Once the cherries are ripe, they’re picked and processed to remove the layers of skin, fruit, mucilage, and parchment surrounding the seed.

There are several main processing methods that farmers use: washed, natural, and honey.

In the washed (or wet) processing method, the cherries are de-pulped immediately after harvest using a machine that strips away the skin and fruit. The beans are then placed in fermentation tanks to remove the rest of the mucilage before being washed and dried.

On the other hand, natural (or dry) processing involves leaving the cherries intact to dry whole instead of removing the fruit.

Honey processing is similar to washed processing and involves leaving a particular amount of fruit on the seeds while it dries. There are several types of honey processing, including yellow, black, red, pink, and white. These colours indicate how much fruit remains on the beans.

Beyond these traditional methods, experimental techniques like aerobic and anaerobic fermentation and carbonic maceration are gaining popularity. These methods involve adjusting oxygen and CO2 levels during fermentation to achieve exciting, new flavour profiles.

Choosing the right coffee for your custom cold brew box

Cold brew is unique because of its long extraction time. This reduces both acidity and bitterness, yielding a smoother cup profile than other methods, with a heavier body and mouthfeel.

This means roasters must use coffee that lends itself to this brew method. Traditionally, cold brew has had flavour notes of chocolate and nuts, so many roasters opt for washed coffees. “Our customers lean towards Central and South American medium roast coffees when they’re looking for a traditional cold brew profile,” Lauren explains.

While flavour depends on the roast profile as much as the processing method, washed coffees are often popular as they have a “cleaner” taste. Taken to a darker or medium roast profile, these are more traditional, but washed coffees are by no means the only option for cold brew. For example, many roasters have started using natural coffees since cold brew extraction enhances their sweetness and fruitness.

“We prefer either the washed (chocolate/cocoa) profiles or the naturals (tropical fruit/floral),” Ruben says. “I am particularly fond of naturals, but that depends a lot on the market you serve.”

Because cherries are left intact during natural processing, the sugars have more time to develop and infuse into the bean. This produces a sweeter, more complex flavour profile with vibrant fruit notes and a fuller body.

“BKON’s brewing technology has also given our customers the ability to create differentiated extractions using unique coffees from regions like Ethiopia and Kenya, creating exciting experiences that mirror the range of their hot coffee offerings,” explains Lauren.

Ruben mentions that picking a coffee for your custom cold brew box ultimately depends on consumer flavour preferences.

“We have tried some varieties that provide a chocolate/cocoa taste, which is preferred by American consumers, such as Lempira and Icatu,” says Ruben. “But we have also used Parainema and Catuai (naturals) that provide a sweet/tropical fruit profile, [like] sugar cane/tamarind, which is preferred by Asian markets, as well as some others that give a more floral profile.”

Roasters can also use honey-processed coffees for their custom cold brew box. The “colour” of the honey processing depends on how much of the mucilage is left on the bean; for example, black honey coffee (high mucilage) has flavours similar to natural coffees, while white honey coffees (low mucilage) are more similar to washed coffees.

Preserving cold brew quality using custom cold brew boxes

No matter which processing method they opt for, roasters must invest in packaging that maintains cold brew’s quality, flavours, and freshness, no matter which coffee they choose.

Bag-in-box packaging, like custom cold brew boxes, is becoming a popular solution to do this. BiBs packaging consists of a high-barrier, multilayer bag with a tap housed in a protective box.

“Bag-in-box is the standard packaging delivery system in the beverage service market,” explains Ruben. “It provides food-safe delivery and preserves quality as well as the organoleptic experience for end consumers.”

The airtight bag and protective outer layer help keep cold brew fresh longer by protecting it from oxygen and sunlight, which can cause oxidation and spoilage.

“We use BiBs for our concentrated cold brew (as well as our cascara concentrate) concentrates, flushed with nitrogen, so we can ensure microbiological conditions and shelf life,” explains Ruben.

Lauren adds: “Shelf-stable bag-in-box has the added convenience of an extended shelf-life, generally one year. Additionally, their designs facilitate inventory stacking, optimise storage space, and ensure easy access for quick use.”

Custom cold brew boxes can also be more cost-effective and lightweight than glass or plastic, reducing shipping and storage expenses. Moreover, as it’s often recyclable, it can be more aligned with consumers’ growing demands for sustainability. A recent PwC survey found that 46% of consumers actively purchase sustainable products, with 80% willing to pay more for them.

BiB packaging uses 85% less plastic than rigid containers, with a carbon footprint eight times lower than glass bottles. Its cardboard exterior is 100% recyclable, and the internal bags are often made from recyclable materials like PLA and LDPE.

At Cold Brew Pak, our custom cold brew boxes are made from eco-friendly kraft paper and corrugated cardboard, helping reduce roasters’ environmental impact while preserving quality and freshness. Our bag-in-box cold brew packaging is also fully customizable, allowing roasters to create visually appealing designs that help their cold brew offerings stand out.