This is a classic dilemma faced by modern specialty coffee brands: you want to offer the convenience of single-serving drip coffee bags, but your brand philosophy is strictly “anti-plastic.”

Can you achieve 100% biodegradable coffee packaging without sacrificing the 12-month shelf life required by your retail partners?

Last year, a rapidly growing UK-based specialty coffee roaster encountered this exact problem and sought help from Tonchant. Their B2B wholesale customers were being lost due to demands from hotel and corporate clients for plastic-free packaging that met stringent ESG (Environmental, Social, and Governance) standards.

Here’s how we helped them completely transform their entire single-pack product line, turning a sustainability challenge into a major competitive advantage.

The Challenge: The “Frankenstein” Packaging Problem

Before contacting us, this roaster had tried to figure out a green solution on their own, but it failed.

They purchased compostable internal filters from Supplier A and biodegradable outer packaging bags from Supplier B, and tried running these products on their existing, older heat-sealing machine.

As expected, they encountered severe issues:

• Machine Blockage: The eco-friendly outer film stretched and melted at high temperatures in their standard packaging machine.

• Poor Sealing: The internal compostable filter was prone to tearing, causing coffee grounds to spill into the cup.

• Stale Coffee: The coffee spoiled because the outer packaging lacked an adequate oxygen barrier. In less than four weeks, their order of premium Ethiopian Yirgacheffe became bland and tasteless.

The Takeaway: They needed a partner who understands how materials and machinery interact. They needed a complete ecosystem, not just disjointed parts.

The Tonchant Solution: A Three-Step Ecosystem

We didn’t just send them a product catalog; we designed a compatible, end-to-end solution from the inside out.

Step 1: The Internal Filter (Tonchant PLA Mesh)

We replaced their original fragile filter with premium PLA (Corn Fiber) mesh rolls. This material is derived from plant starch and is fully biodegradable under industrial conditions (compliant with EN 13432). More importantly, it has the same tensile strength and silky texture as traditional nylon, ensuring a superior brewing experience while protecting consumers from microplastics.

Step 2: The Outer Barrier Layer (Compostable Film)

This is the most challenging problem in the industry: coffee needs to be isolated from oxygen and moisture. We provided a custom-printed, multi-layered compostable roll film. Instead of using traditional aluminum foil, we employed an advanced bio-based barrier coating. This results in an Oxygen Transmission Rate (OTR) low enough to guarantee a shelf life of 9 to 12 months—keeping the nitrogen firmly locked inside the packaging.

Step 3: Hardware Calibration (Ultrasonic Sealing)

You can’t use old-fashioned, high-temperature heat-sealing machines to handle sensitive biological materials. Since they were already upgrading their production capacity, the roaster invested in a Tonchant Fully Automatic Drip Coffee Packaging Machine. We equipped the machine with Ultrasonic Sealing Technology. Instead of using heat to melt the PLA mesh, the machine utilizes high-frequency sound waves to instantly fuse the edges. This eliminates tearing issues and allows the machine to operate smoothly at high speeds without causing thermal damage to the eco-friendly film.

The Result: Growth Through Sustainable Development

Transformation requires careful planning and testing, but launching a 100% biodegradable drip coffee line changed the course of their business.

• Zero Downtime: Because both the film roll and the machine are designed by the same manufacturer (Tonchant), they operate flawlessly together. There is no more molten plastic stuck to the sealing clamps.

• Extended Shelf Life: The new bio-barrier film successfully preserves roasting profiles and easily passed the stringent 6-month taste test required by high-end supermarkets.

• 40% B2B Customer Growth: Armed with certified compostable packaging, the roaster successfully marketed its products to luxury eco-resorts and corporate offices that had previously rejected its plastic-lined offerings.

Brand Inspiration

Green and eco-friendly practices are no longer just a marketing gimmick; they are an engineering challenge. Trying to mix environmentally friendly materials from different suppliers can easily lead to a decline in coffee quality and machine malfunctions.

At Tonchant, we manufacture the filter cartridges, print the outer films, and build the packaging machines. We ensure that every component fits perfectly.

Are you ready to successfully transition to biodegradable packaging? [Contact Tonchant Today] to request a sustainability sample pack, or consult with our packaging engineers about upgrading your current production line.