Industry Knowledge

Why Coffee Chains Are Ditching Immersion Cold Brew

There seems to be something about making cold brew coffee in large batches, patiently waiting 12+ hours, and enjoying a fresh glass. This slow and methodical immersion process is simple and romantic. However it creates limitations and obstacles if a business is trying to grow a consistent high-quality cold brew program.

Operators are beginning to transition from their traditional immersion cold brew methods to alternatives that are less labor-intensive and less prone to error.

 In this article, we’ll explore how this emerging trend is unfolding, including:

  • The motivations for rethinking standard immersion in a cafe setting

  • Popular alternative brewing solutions that enable brands to scale

  • Realizing the growth opportunities in and outside of the cafe.

By the end, you’ll understand why this trend is evolving and be equipped to evaluate what makes sense for your coffee brand.

The Hidden costs of immersion cold brewing

On the surface, making cold brew in cafe with an immersion brewer appears a cost-effective option.

But if you’ve operated or managed a group of coffee shop locations you’ve no doubt come face-to-face with the costs that a simple COGS spreadsheet doesn't reveal.

It’s a burdensome process. Set up takes upwards of twenty-five minutes, brewing takes 12+ hours, then filtering and cleanup takes thirty to fifty minutes. When your team’s busy serving customers and providing great experiences, or focusing on other tasks, this process can be easily muddled, creating inconsistency for customers in-store.

Food safety management is not just a hassle, but a risk. There’s no federal standard for cold brew in the FDA’s Food Code, which has resulted in local state health inspectors varying enforcement protocols. This may result in additional work such as applying for variances or developing HAACP plans to comply. Further, there are possible food safety risks involved when cold brew, a low-acid food, is combined with a reduced oxygen environment like a keg or when it’s not stored at the proper temperature.

The training curve leaves room for error. Making a batch of immersion cold brew doesn’t require craft, but when you’re trading staff back and forth between locations—and frequently onboarding new team members—the training curve starts to feel like a limitation to the standard immersion method’s simplicity.

Controlling water quality in foodservice establishments is not easy. Poor water quality can influence product taste. Filtration systems in retail settings are not consistently managed or effective enough for coffee brewing demands.

Running out before the day’s end is costly. We recently spoke to one coffee chain that reported their busiest location is also their most negatively reviewed—and most of the negative reviews are that the location is frequently out of cold brew. Creating inconsistent experiences has consequences for customer loyalty and top line.

These costs compound in times of labor scarcity and high turnover like we’re experiencing currently. For chains that want to operate and grow in a smarter way, these are meaningful roadblocks. It’s no surprise that many are turning away from the immersion cold brew method.

What Other Options Do Coffee Chains Have for Cold Brew?

Beyond the bucket brewers there are two primary alternatives that can support the high-volume potential of a cafe. Most coffee brands have considered these traditional options:

  1. Cold brew kegs made off-site eliminate the labor and time of on-premise brewing, but require refrigerated distribution and storage—a big cost burden, with questionable margins.

  2. Shelf-stable concentrates provide a robust supply and simplify operations, but have historically delivered low-quality flavors that brands are not proud to serve.

It makes sense why immersion cold brew became so popular. It’s more cost-effective than cold chain kegs, and the flavor is superior to shelf-stable concentrates.

Great news: there’s a proven alternative that breaks through these limitations and it’s the one drawing growing coffee brands away from immersion brewing.  

Reverse Atmospheric Infusion® (RAIN® for short) is a technology that results in shelf-stable cold brew concentrates that defy industry limitations by delivering a consistent fresh-made cold brew experience.  

RAIN extractions are made with your brand’s coffee in BKON’s commercial brewing facility, packaged and thermally processed at a partnered co-packing facility, and arrive at your cafe locations in shelf-stable Bag-in-Box (BiB) containers that are easy to store and use.

BiB in Kegerator

In contrast to immersion cold brew, RAIN extractions are specifically designed to bring out a coffee’s unique flavor profile with the same degree of control that is associated with hot brewed coffee—and those flavors remain consistent for 6 months when shelf-stable. This has led companies like Peet’s & Allegro Coffee to adopt RAIN-produced cold brew coffee.

How it’s making an impact in the cafe setting

No-prep, fast cold brew coffee service from any team member. Baristas serve the cold brew from dispensing systems that dilute and chill straight from the Bag-in-Box or mix it with water in a standard corny keg. It’s a consistent, simple process that any employee can execute perfectly without any special training.

Positive employee and customer experience. RAIN extractions are simply dispensed and served, enabling baristas the satisfaction of creating more direct, less distracted engagements with customers. Switching to Bag-in-Box means your team can focus on opening and closing tasks without rushing through cold brew setup and takedown as well.

Every customer gets the drink they want (because you never run out). The immersion method produces a limited amount of cold brew each session. If you run out for the day, there’s none left until the next. A shelf-stable solution stores enough product for multiple days-worth of service and never has to disappoint a customer.

Greater versatility. High quality concentrates simplify the execution of beverages, creating a speedy way to deliver additional menu offerings.  

Growing coffee chains are using this modernistic approach to simplify processes and optimize labor utilization—without compromising on flavor or the customer experience.

Overcoming Food Safety Hassles

Food safety management has been an issue for coffee brands, so much so, that the NCA recently published a cold brew safety guide for retailers. As brands grow, there’s a lot more exposure and locations to manage.

Further, health code regulations often require that cold brew made in-store has to be served in-store. In most locales, you cannot brew internally, then fill containers to be used in other channels, like wholesale or grocery.

RAIN cold brew coffee, on the other hand, is brewed and packaged in facilities that are certified with finished product ready for use in any sales channel. These thermally processed products eliminate microbial growth from occurring. This is another key reason established chains are pivoting to ready-made, shelf-stable concentrate. 

Sales Channel Growth: You Can’t Do This with Immersion Cold Brew

RAIN extractions can be scaled up and down in concentration without compromising flavor quality and consistency. This enables coffee brands to use a single extraction to create products for a variety of use cases and environments:  In-cafe service, CPG for retail and direct to consumer, and dispensing systems for workplaces and restaurants.


Ready to Elevate your Cold Brew Program?

We’re looking for coffee businesses that are eager to add simplicity and new sales potential to their cold brew program

Reach out today.

Why Shelf-Stable Cold Brew Is Taking Over the Coffee Service World

For most coffee professionals, watching a barista pop open an unrefrigerated box of cold brew coffee and serve customers from it would trigger all kinds of alarm bells. 

Conventional wisdom states that cold brew is best when brewed fresh and refrigerated for short periods of time. Anything that can be served off the shelf must taste utterly incomparable—right?

Despite this commonly-held belief, shelf-stable cold brew is driving the cold brew programs of respected roasters like Segafredo ZanettiParlor Coffee and Joe Coffee.

In this article, we’ll explore why shelf-stable is inspiring a rethinking around cold coffee freshness, flavor, and business opportunities, including…  

●      Why modern shelf-stable cold brew is breaking the old school rules

●      The advantages coffee brands are experiencing without cold chain

●      How established companies are increasing market share with shelf-stable coffee

By the end, you’ll have an insider’s look at how the cold brew industry is innovating and why this is a direction worth exploring for your brand’s cold brew program.

Why Shelf-Stable Cold Brew Hasn’t Worked Historically

Shelf-stable cold brew coffee has been around for years, but there’s a reason it never appealed to brands that prioritize quality flavor experiences: the heat treatment that sterilizes the liquid coffee and makes it shelf-stable has a striking negative impact on flavor.

Customers want to enjoy the distinguishable coffee flavor of fresh cold brew that they know and love from their favorite coffee brands, and shelf-stable historically has just not been an option for brands that consider themselves quality-conscious.

As a result, brands tend to either surrender to the cold supply chain as their only option or pursue alternatives like over diluting shelf-stable cold brew to reduce the negative impact on flavor.

What’s Different About Parlor Coffee’s Shelf-Stable Cold Brew?

If you’ve tasted the shelf-stable cold brew coffee from roasters like Parlor Coffee, Segafredo Zanetti, and Joe Coffee , you’ve no doubt noticed that it didn’t have the muted flavor we just described as standard for shelf-stable cold brew. 

Instead, you’re experiencing all the flavor notes you taste with their hot coffee. Parlor’s shelf-stable cold brew tastes freshly made with notes of milk chocolate, vanilla, and melon.

Quality-focused roasters are using RAIN technology to produce shelf-stable cold brew with fresh-brewed flavor that lasts for half a year and most authentically represents their brands.

RAIN differs from traditional methods by carefully removing the air trapped in coffee particles, changing infusion process outcomes.  This results in fresh brewed flavor that withstands thermal processing to deliver what you would taste on the cupping table, but as a shelf-stable product.

It's easier and more affordable for us and for our customers to store. We can keep more on hand for that unexpected sunny day when cold brew seems to be the only drink customers want, without sacrificing quality.”

— Stephanie Dana, Parlor Coffee

For the first time, coffee brands with strict quality standards have the ability to commercialize shelf-stable cold brew options that deliver complex and nuanced flavor profiles for 180 days.

Accelerated Growth Unlocked by Shelf-Stable Cold Brew

RAIN extractions are sent to co-packers for thermal processing and packaged in shelf-stable formats like Bag-in-Box (BiB) containers. Since the finished product doesn’t require refrigeration for transit or storage, coffee roasters are free to reimagine their approach to sales and growth without the limitations of the cold supply chain. 

“The doors have opened for us to get our coffee into spaces that might have otherwise been complicated by cold transportation or cold storage needs. We’ve been able to develop new and more robust coffee programs with large office spaces, distribute a consistently delicious ready-to-drink product to long-term partners outside of New York, and even explore direct-to-consumer applications.” 

— Stephanie Dana, Parlor Coffee

We’ve seen roasters experience new advantages, including:

  • OPERATIONAL OPTIMIZATION AND CUSTOMER EASE OF USE

    For restaurants, offices, and other food service establishments, cold storage is scarce. Shelf-stable cold brew requires less cold storage space which means less deliveries for coffee brands and more convenience for the operator.

  • LEVERAGING OF CORE DISTRIBUTION CHANNELS

    Shelf-stable cold brew can be shipped or delivered the same way as dry coffee…unrefrigerated. Brands are streamlining their distribution methods, further adding to their operational optimization.

  • INCREASING GEOGRAPHICAL REACH THROUGH LARGE DISTRIBUTORS

    Cold chain distribution is highly regionalized and expensive. The 90-day shelf life of cold chain products further complicates brands’ ability to distribute outside their region. The more time it takes to move product, the more the product shelf life is ticking away. Large distributors often require a 180+ shelf life for products. The most effective way to increase a brand's reach is through large distributors. Non-refrigerated products with longer shelf lives position brands for greater access to these distributors. 

  • CREATING MULTI-CHANNEL CONSISTENCY

    Brands are creating the same in cafe experience everywhere their cold brew is served, and wholesale customers benefit by offering the tasting experience consumers expect from a specific brand. Consumers have confidence in what they’re getting, no matter where they purchase your cold brew.

All of this is occurring while maintaining a high standard of coffee flavor and brand alignment.

Also Read: How Caffe Vita Uses Shelf-Stable Cold Brew to Access New Sales Channels

Want to Taste the RAIN Shelf-Stable Difference?

We partner with established quality-conscious coffee brands who want to explore shelf-stable cold coffee applications. 

Is that you? Reach out today.

How Cold Coffee Becomes Shelf-Stable (Without Losing Flavor)

The scientific breakthrough of aseptic thermal processing to make shelf-stable beverages is nothing short of a modern miracle.

But, the ability to create shelf-stable cold coffee without destroying the coffee’s nuanced and complex flavors is only a few years old. In this article, we’ll explore what’s different about this new approach to cold coffee, including:

  • A quick walkthrough of the three stages to make a shelf-stable coffee

  • Why not all coffee extraction methods perform equally when heat-treated

  • How coffee brands can make shelf-stable cold brew that’s just as delicious and complex as their hot coffee

 

Step 1: It Starts with Coffee Extraction

Commercial cold brew coffee extraction most commonly occurs in large production vats, similarly or even identical to the containers used to brew beer. These containers are designed to control only a few main variables: total extraction time, temperature (+/- three degrees), and sometimes agitation. Since these are often open systems, steeping coffee is exposed to the air with limited controls. 

At BKON, we approach the extraction stage differently. Our RAIN technology operates within a completely closed system that relies on a unique combination of parameters that are atypical to other brewing methods, including: 

  • Brewing at a variety of ambient temperatures

  • Controlling strength & frequency of negative pressure environments

Side view of the BKON STORM XL Brewer

These precise controls enable us to produce a unique recipe for each coffee that achieves our partners’ desired flavor profile with consistency that lasts 180+ days.

“Control is the key factor here. We use a Six Sigma approach and get really fine-tuned with how we create extraction recipes. That’s something you don’t see with other methods.” 

— Itamar Loss, BKON


Also Read: Why Shelf Stable Cold Brew Is Taking Over the Coffee Service World

Step 2: Batching and Mixing 

This second stage is where dilution occurs for straight black SKUs and where other ingredients are integrated into the coffee extraction for formulated products. Oat milk lattes and flavored cold brew are examples of products where batching and mixing are necessary. 

Co-packers typically manage this process in large tanks equipped with different types of agitators and mixers which blend the ingredients into a single homogenous product. 

Step 3: Thermal Processing

Shelf-stable products are heat treated to stop microbial growth and keep beverages safe for non-refrigerated storage and transit. The FDA regulates that coffee, as a ‘low acid food’ (those with a pH level at 4.6 or above) must undergo processing to become shelf-stable, which allows it to be stored and shipped without refrigeration. 

The most common methods used by co-packers for cold coffee are:

  • Ultra High Temperature (UHT) + Aseptic Filling — In this method, the product is heated between 280° to 300° F for only 2 - 6 seconds to sterilize the liquid. Pre-sterilized packaging such as Schoelle bags and TetraPak cartons are essential to the product remaining microbial-free after filling.

  • Retort for Canning — This type of thermal processing does not require the beverage to be sterilized prior to packaging. First the cans are filled with the beverage and sealed.  The packaged product is then heated with steam and/or water at a temperature of 160° to 175° and held for 7-15 minutes.

Similar to leaving a pot of coffee on heat for too long, traditional thermal processing tends to overcook the flavor of industrial coffee extractions.  For this reason, even UHT processing that only occurs in a matter of seconds results in compromised flavor and increased bitterness. But the initial extraction method used can have a profound positive effect on the outcome of heat-treated products.

For coffee extractions created via RAIN technology, the difference is striking. It tastes like the coffee does on the cupping table, or when brewed fresh—every bit as complex and aromatic, without typical negative characteristics of shelf-stable coffee.

“We’ve done many blind tastings where people can’t tell which coffee is from the cold chain and which is shelf-stable from the RAIN method. We don’t see that loss of flavor quality during thermal processing with our extraction method.” 

— Christina Stevens, BKON

Once thermal processing is complete, pallets of packaged products are  sent off to customers and distributors. 

 
Caffe Vita Shelf-Stable BiB and Cans
 

Now that brands can create shelf-stable cold brew that exhibits the distinguished flavor their customers know and expect, a new range of cold coffee advantages are available.

  • Reducing costs by eliminating cold storage and transit

  • Increasing customer acquisition through a product that’s simple to manage and use

  • Expanding reach to new locations through large distributors

  • Offering the same consistency across multiple channels and product types

ALSO WATCH: Parlor Coffee’s Shelf-Stable Cold Brew Program

Want to explore how shelf-stable cold brew can simplify your operation and increase sales potential? Reach out today.