Fresh Roasted Coffee & Packaging: 

Ever tried to brew a great cup from stale coffee beans or pre-ground coffee? If you have, you’ll know it’s almost impossible. Coffee is a fresh food, and like all fresh foods, it has a limited window where flavour and aroma are at their peak.

In this guide, we’ll explain what fresh roasted coffee really means, why packaging matters, and how we at Carlini Coffee protect the quality of every bean we roast.

What Does “Fresh Roasted Coffee” Mean?

When coffee is freshly roasted, it enters a degassing phase — releasing large amounts of carbon dioxide (CO₂).

• In the first week after roasting, CO₂ levels drop by around 30% (and not in a straight line).

• As weeks pass, CO₂ release slows, and with it, the aromatics and flavour complexity begin to fade.

Think of it like a pressure valve: strong at first, then gradually weakening over time.

Why Coffee Packaging Matters

Coffee continues to age even inside sealed packaging. That’s why specialty coffee packaging has evolved to use multi-layer laminated films — typically 3-ply for maximum protection.

• Middle layer: Foil or metallic barrier to lock in freshness.

• Inner layer: Food-grade safety.

• Outer layer: Branding, product details, and visual appeal.

The Role of One-Way Valves

Most modern coffee bags feature a one-way valve that:

• Allows CO₂ to escape without letting oxygen in.

• Prevents bag rupture from gas build-up.

Freshly packed coffee often appears puffy until the valve activates. Variations in valve pressure, temperature changes, or altitude shifts (e.g., air travel) can cause bags to swell or compress — both are normal.

Why We Use Pre-Made Coffee Bags

At Carlini Coffee, we choose pre-made gusset bags over roll-stock “pillow” packs because:

• They look more premium (thanks to the K-seal base).

• They offer better shelf presentation.

They cost up to 40% more and are trickier to run on automated lines, but the quality is worth it.

Shelf Life & Freshness Philosophy

While thicker foil layers can extend shelf life, factors like bean origin, roast depth, and storage temperature have a bigger impact.

We don’t believe in supermarket-style 12–24 month “Best Before” dates. Instead, we recommend enjoying coffee within 45–60 days of roast for peak flavour.

Our Packaging & Labelling Standards

• Roast date printed on every bag for transparency and batch tracking.

• Brand new cartons for shipping, except in rare cases for unusual sizes.

• In-house label printing for our own and private label clients (monochrome; colour labels via specialist suppliers).

High-Capacity, Quality-Controlled Packing

Our roasting facility features:

• Three automated packaging lines

• Capacity to pack up to 420 kg/hour in 1kg gusset bags

• Strict quality requirements for bag construction to ensure smooth filling and sealing

We reject low-quality gusset bags that compromise the packaging process — and we offer consultation services to help clients choose the best packaging for their coffee.

Key Takeaways for Coffee Lovers & Roasters

• Freshness starts at the roast date — packaging can slow staling but not stop it.

• One-way valves are essential for preserving flavour and preventing oxygen damage.

• Premium pre-made bags enhance both quality and presentation.

• For the best cup, buy coffee in quantities you’ll use within 45–60 days.