Structures for ground coffee
Ground coffee is sensitive to oxygen, moisture and light. The pouch structure must block all three. Common formats include flat bottom pouches, stand up pouches, side gusset bags and rollstock film. Flat bottom pouches stand well on shelf and hold a lot of coffee for their footprint. Stand up pouches work for smaller retail packs. Side gusset bags suit larger formats. Rollstock film runs on vertical form fill seal lines for high-volume packing.
Material choice follows the barrier requirement. PET/AL/PE gives the highest barrier because of the aluminium foil layer. PET/NY/PE offers good barrier without foil and survives drop tests. Kraft paper laminates give a natural look but need an inner barrier layer to protect the coffee. Mono-material PE and PP recyclable structures are available where recycling matters. PLA/PBS compostable options exist for brands with industrial composting streams.
Barrier and degassing
Freshly roasted coffee releases carbon dioxide for several days. If the pouch is sealed without a way out, the gas builds pressure and the pack inflates or the seal fails. A one-way degassing valve lets CO2 escape while keeping oxygen out. Valves are common on ground coffee packs, especially for whole bean and ground roast. Without a valve, you must rest the coffee before packing, which adds time and inventory.
Oxygen transmission rate (OTR) and moisture vapour transmission rate (MVTR) are the numbers to compare. Foil structures give the lowest OTR. Metallised PET is a mid-range option. Clear mono-material films have higher OTR and suit shorter shelf life. Light also degrades coffee oils, so opaque or metallised layers help. If the pack needs a window, keep it small and place it away from the main coffee mass.
Filling and sealing
Ground coffee is usually filled by auger or volumetric cup. The fill method affects the amount of air left in the pouch. A good seal needs clean flanges: coffee dust on the seal area causes channels and leaks. Inline brushing or air jets before sealing reduce rejects. For valve pouches, the valve is applied before filling or during the pouch-making step, depending on the machine.
Seal parameters matter. Temperature, pressure and dwell time must match the film. Too cold and the seal is weak; too hot and the film stretches or burns through. Verify seals with peel tests and burst tests at start-up and during the run. For rollstock, check that the film tension is correct so the print stays in register. A stable filling line is the cheapest way to avoid leakers.
Cost drivers
The main cost drivers are structure, print method, order quantity and add-ons. Foil laminates cost more than clear films. Rotogravure printing has a higher setup cost but lower unit cost at volume; digital printing has no plate cost and suits small runs. Clover offers digital print from 100 pcs for pouches and 10 kg for film. Rotogravure starts from 10,000 pcs or 200 kg. Lead time is 10-15 working days for digital after artwork approval and 20-25 working days for rotogravure.
Add-ons change the price: one-way degassing valve, zipper, tear notch, window, spout and cap, carry handle, hang hole. A valve and a zipper are the most common on ground coffee. Keep the design simple to control cost. A smaller pouch with the same barrier can be cheaper than a larger one, but check that the fill weight fits. Free stock pouch samples are available; the customer pays courier only.
Sustainability rules
Recyclability depends on the local collection system. Mono-material PE or PP pouches are easier to recycle than mixed laminates, but they need a compatible barrier coating to protect coffee. Compostable PLA/PBS structures require industrial composting, not home compost. Degradable options exist but check the claims and the destination market rules. Some countries restrict the word 'recyclable' unless a collection stream exists.
If you choose a recyclable mono-material, expect a shorter shelf life than foil unless the film has an EVOH or similar barrier layer. Test the coffee at 3, 6 and 9 months to confirm. For compostable packs, keep the ink and adhesive compatible with the composting standard. Always ask for the material datasheet and any certification from the factory. Certifications belong to the manufacturing partner, not to Clover.
Common mistakes
Mistakes that ruin a roast: sealing over coffee dust, using a clear film for a long shelf life, skipping the degassing valve, and choosing a pouch size that leaves too much headspace. Headspace holds oxygen. Another mistake is printing before the artwork is final; changes after plates are made add cost and time. For digital print, changes are easier but still need approval before the run.
Also check the fill weight against the pouch dimensions. A pouch that looks right on screen may not hold the target weight with the right headspace. Order samples and run a fill trial. Confirm the zipper position and the tear notch height. If you use a valve, make sure it is placed where it will not be covered by the label or the shelf. Small details decide whether the pack survives the supply chain.