A Confidential Coffee Packaging Project

BioPouches worked with this customer to improve both the visual design and the physical packaging of its existing coffee pouch. This case study documents that packaging-development project: what the customer had before, what they wanted to change, what BioPouches did, and what the resulting pouch was like.

The Packaging Before the Redesign

The customer already had an existing printed coffee pouch in use before approaching BioPouches. The packaging was functional, but the customer wanted the package to better represent the product and improve the overall packaging presentation.

This project was not a response to a packaging failure. It was a packaging-improvement request from a brand that wanted a stronger presentation and a pouch that better matched how it wanted its coffee to be perceived.

What the Customer Wanted to Improve

The customer's objectives covered both the visual design of the packaging and the physical pouch itself:

Treating these as connected requirements, rather than a design task and a manufacturing task handled separately, shaped how BioPouches approached the project.

How BioPouches Approached the Project

BioPouches worked on the packaging as a complete package rather than treating artwork and pouch manufacturing as unrelated tasks. The process began with reviewing the customer's existing pouch and understanding specifically what the customer wanted changed, both in how the package looked and in how it functioned as a coffee pouch.

From there, the project moved into developing a more coffee-specific visual direction alongside evaluating the pouch requirements needed to support that design and the product itself. Once a direction was agreed with the customer, the packaging was prepared for production and the resulting package was reviewed before finalizing the project.

Approaching the redesign this way meant design decisions, like layout and color, were made with an awareness of how the finished pouch would actually be produced and printed, rather than a design being created in isolation and handed off afterward.

Design Direction

The new visual direction uses stronger coffee-related visual cues, including coffee-oriented colors and coffee bean imagery, aimed at giving the package a clearer, more recognizable coffee-packaging appearance. Information hierarchy was also part of the redesign, organizing the pouch's design elements so the product presentation is clearer at a glance.

Why Coffee Packaging Is More Than Artwork

Roasted coffee packaging involves considerations beyond how the pouch looks. Depending on the project, this can include aroma protection, environmental exposure, closure and degassing, since roasted coffee continues to release gas after roasting and can be affected by oxygen and moisture exposure over time.

BioPouches manufactures coffee pouches with options such as one-way degassing valves and resealable closures, depending on the specific project's requirements. Not every BioPouches coffee pouch includes these features, whether a given project uses a valve, a specific closure, or a particular material structure depends on that project's own requirements, and this case study does not extend those options as a blanket description of every coffee pouch BioPouches produces.

Before-and-After Packaging Visualization

Before-and-after packaging visualization. Customer identifying information has been concealed for confidentiality; visual presentation is used to illustrate the packaging redesign.

The Resulting Coffee Pouch

The project resulted in a redesigned coffee pouch with a more coffee-focused visual identity and an updated packaging presentation based on the customer's requirements. The redesign addressed both the visual direction the customer wanted and the physical packaging changes needed to support it.

What Other Coffee Brands Can Learn From This Project

When evaluating a coffee pouch redesign, brands generally benefit from considering the physical packaging and the visual design together rather than treating them as separate projects. Points worth working through before starting a redesign include:

• Pouch format

• Material requirements

• Coffee protection requirements

• Degassing valve requirements

• Closure

• Dimensions

• Printing

• Artwork

• Filling process

• Order quantity

Working through these alongside the visual direction, rather than finalizing artwork first and fitting it to a pouch afterward, is part of what shaped how this project was handled.

BioPouches acted as the custom flexible packaging manufacturer responsible for this project, covering both the pouch development and the production of the approved design.

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