In a new article on Packaging World, Pat Reynolds highlights the history of Westrock Coffee and their expansive Arkansas manufacturing facility that includes advanced processing and packaging technology for the RTD coffee market. Included in the line are multiple ProMach product brands including Allpax, ID Technology, Fogg and others.
When Scott Ford launched Westrock Coffee, his vision was to provide better compensation for coffee farmers while delivering high-quality coffee products. Starting with roasting and grinding operations, Westrock quickly expanded into single-serve coffee and later acquired S&D Coffee. When the pandemic hit, the company adapted by focusing on coffee extracts, ultimately leading to their entry into the ready-to-drink (RTD) coffee market. With the acquisition of a large facility in Arkansas, Westrock positioned itself as a major player in the growing RTD beverage sector.
As the ready-to-drink (RTD) beverage market continues its rapid expansion, innovation and efficiency in packaging are more critical than ever. This growth has been especially evident in RTD coffee, where precision, speed, and scalability play a vital role in meeting consumer demand while maintaining product integrity and quality. Westrock is stepping up to meet these challenges with the help of sophisticated equipment, including a custom-designed retort system from ProMach product brand Allpax. Their collaboration is setting new standards in RTD coffee packaging.
The Westrock and Allpax Partnership
As Westrock scaled its production of RTD coffee beverages, it needed equipment that met the demands of a high-output environment and delivered reliability. Allpax, known for its expertise in retort processing solutions, provides the technology and support Westrock needs to elevate its packaging line and stay competitive.
Retort processing is a key method for ensuring the longevity and safety of RTD coffee products, which often require stringent thermal processing to maintain their freshness and flavor. Allpax’s retort systems are designed to efficiently handle the unique requirements of the RTD coffee sector, offering a solution that balances speed with safety—two crucial factors in production.
Allpax provided 11 full-immersion rotary retorts for Westrock’s operation, which are required for the sensitivity of the product. David Cohen, technical sales engineer for Allpax explained the process in the recent Packaging World article. “There’s a top tank with water heated to around 275°F and then there’s the bottom tank. Uncooked containers in large baskets go into the bottom tank, the door is closed, and a connection valve is opened to let the water from up top flow into the bottom tank, fully submerging the containers. Also important is that because the coffee is quite viscous, we constantly rotate the baskets during the cook cycle so that the liquid contents in every can are evenly mixed. Otherwise it would take too long to get the center of the product up to the temperature needed to render the containers shelf stable. And with beverages like these, some of which contain dairy components, the quicker you get up to kill temperature and then back down to chilled the better your finished product will be.”
Meeting Market Demands with Advanced Packaging Solutions
For Westrock, keeping pace with the market demand means relying on equipment that offers both flexibility and scalability. Allpax’s automated retort systems allow Westrock to rapidly scale its operations while maintaining consistent quality standards. And, by automating critical parts of the packaging process, Allpax’s retort system enhances Westrock’s efficiency without compromising on quality control. This balance is crucial for large-scale operations where even minor inefficiencies can have significant impacts on output and profitability.
Allpax has long been recognized as an industry leader in retort processing, providing solutions that cater to a wide range of industries, including food and beverage. In the case of RTD coffee, retort technology is essential for ensuring product safety by applying heat to sterilize the product and extend its shelf life. This process allows Westrock to package high-quality coffee beverages that can be shipped and stored for extended periods without losing their flavor or freshness.
To learn more about the advanced technology on the entire Westrock packaging lines, including other ProMach product brands like Fogg, ID Technology, and more, read the Packaging World article HERE.
