Top take-outs

  • Success in RTD coffee is about translating your brand’s signature flavour into a shelf-stable format
  • Protect your brand equity by maintaining consistent taste, aroma and overall quality
  • Preserve flavour and ensure product stability and shelf life with effective processing
  • Tightly control key processing variables, such as extraction parameters, heat treatment and oxygen exposure

When it comes to coffee, flavour is the strongest differentiator. Consumers associate a brand’s products with its specific taste, aroma and coffee experience.

The question many coffee producers face when considering entering the ready-to-drink category is how to replicate that signature flavour in an RTD format? Can you deliver the taste and aroma your consumers expect in an RTD coffee, with repeatable and lasting quality? Or does a move into RTD coffee risk diluting or damaging your brand identity?

Expert support is at hand

Replicating your signature flavour in an RTD coffee format can certainly be challenging, especially when shelf-life requirements and processing conditions differ significantly from traditional coffee preparation. But the good news is, it can be done.

By leveraging the knowledge and experience of our coffee team and deploying the latest processing technologies, you can create quality RTD products that align with your traditional coffee products. You can also leverage our innovation ecosystem to devise and test novel RTD coffee recipes for new consumer groups – attracting younger consumers in search of an indulgent coffee treat or a mid-morning pick-me-up.

Decide on a flavour profile

The first step is to understand the attributes that you and your consumers value most in your coffee; to define the ideal flavour profile. Once this is clear, we can tailor a production process with finely tuned technologies to achieve it. By carefully controlling the many parameters that affect product quality and flavour – from the raw ingredients, through each processing step, to the packaging of your end product – we can help you get the results you’re looking for.

Own production or co-packing?

Our processing and packaging solutions are designed to safeguard the quality of your coffee by minimising the negative impacts of each production step. Although based on standard lines, each individual solution is customised and its processing parameters adjusted to give you a coffee with the aroma, taste and texture you want.

If you’re not ready to invest in a processing line, co-packing is a great way to speed up your time to market, allowing you to take your first steps into the RTD coffee world without a major capital investment. Talk to us about finding a suitable co-packer in your region.

The challenges of RTD coffee production and how we tackle them

Creating a successful RTD coffee product involves navigating a range of production and formulation challenges. Understanding these is key to achieving the desired quality and consumer experience. In the following sections, we outline the six most common challenges and the approaches used to address them.

Coffee and tea extraction equipment

1. Extraction – method and key parameters

1. Extraction – method and key parameters

Our extraction systems use the method known as percolation – which is widely regarded as the optimal method for RTD coffee production due to its efficiency and scalability. Compared to immersion, percolation maintains a strong concentration gradient throughout the process, enabling the efficient and selective extraction of desirable flavour compounds. It also enables better control over extraction speed, helping to limit harsh or bitter compounds. This makes it particularly suitable for producing consistent, high-quality coffee extracts for ready-to-drink applications.

 

Key process parameters such as the coffee-to-water ratio, extraction time, and temperature directly influence yield and flavour profile, determining not only how much is extracted, but also which compounds are extracted at different stages of the process. Poor process control can lead to either insufficient extraction, resulting in a thin and underdeveloped flavour profile, or excessive extraction resulting in bitterness and astringency.

Tetra Pak plate heat exchanger

2. Heat load, post extraction

2. Heat load, post extraction

Every process step after extraction can impact the delicate aroma of your coffee. In the heat treatment step, a high temperature is needed to ensure food safety. However, you want to keep the overall heat load as low as possible since prolonged heat exposure affects the delicate coffee aromas, as well as having an impact on flavour-giving substances, vitamins, colour, proteins and functional ingredients like stabilisers.

 

Thanks to rapid heating and cooling, the overall heat load of our continuous UHT process for RTD coffee in aseptic cartons is low, thereby minimising the impact on your product.

Tetra Pak Radial Jet Mixer

3. Effects of vacuum and air exposure

3. Effects of vacuum and air exposure

All RTD coffee products share two important characteristics: they are sensitive to both air incorporation and vacuum. Air exposure accelerates oxidation and causes flavour deterioration, while vacuum strips volatile aroma compounds from the extract. The goal is therefore to mix efficiently without introducing air or applying a vacuum.

 

In addition, many RTD coffees require pH adjustment, so your mixing system should maintain a fully homogeneous batch at all times, enabling rapid and accurate acid or buffer dosing. When the mix is not fully homogenous, pH adjustments can create a production bottleneck.

 

The Tetra Pak® Radial Jet Mixer (RJM) is well suited for RTD coffee since it provides highly efficient (nonvacuum) mixing with minimal air incorporation, while also ensuring a uniform distribution of all components throughout the batch.

Tetra Pak Pasteurizer B

4. Sedimentation

4. Sedimentation

Coffee contains insoluble materials that can remain suspended after brewing and processing. Over time, these particles can settle, causing sedimentation.

 

There are several ways to address this issue: minimal heat treatment, efficient homogenization and, if your recipe allows for it, the addition of stabilisers.

Tetra Pak Homogenizer

5. Textural issues

5. Textural issues

With the correct heat treatment, you can limit the creation of proteins that may occur in plant- or dairybased coffee products, thereby avoiding the formation of a grainy texture.

 

Homogenization and the use of functional ingredients can help you achieve a smooth texture in your RTD coffee products.

Tetra Prisma Aseptic carton packages

6. Flavour loss over time

6. Flavour loss over time

RTD coffee’s taste and aroma, and to some extent its texture, changes over time.

However, the material layers in our aseptic carton packaging are designed to protect the coffee from exposure to oxygen, moisture and light, helping to preserve your product’s properties and enabling a longer shelf-life.

Let’s navigate the challenges together

While the above section outlines the most common challenges associated with RTD coffee production, in reality every product presents its own unique set of requirements and opportunities.

As Tetra Pak coffee expert Anders Löfgren explains:

“There is no one-size-fits-all solution. In collaboration with you, our team can help navigate the challenges of RTD coffee production, develop tailored solutions and ensure your product is positioned for success in the market.”

Trial, analyse and perfect your recipe

The technical teams at our twelve Product Development Centres are on hand to support your recipe development and run trials, helping you fast-track new RTD coffee products to market.

 

Leveraging our support, you can create quality RTD coffee products that both your existing consumers and new ones will appreciate, generating revenue streams for years to come.

Ready-to-drink coffee

RTD coffee is one of the fastest-growing beverage categories in the world today. Take this opportunity to expand into convenient, premium, on-the-go formats and unlock new revenue streams. Leverage strategic and practical support from our expert teams to help you succeed.

Get in touch with us!

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