Customer Overview
US Roast Coffee serves more than 100 coffee shops and cafés across the United States. Unlike many coffee roasters that rely exclusively on fully printed packaging, US Roast uses a flexible fulfillment model that combines blank pouches with custom labels, allowing them to efficiently support a large variety of customer-specific products.
What began as an inquiry about stock coffee bags evolved into a comprehensive packaging partnership that now includes custom blank pouches, branded retail packaging, 5 lb coffee bags, and ongoing product development.
The Challenge
US Roast was interested in Enviro Flex Pack's stock coffee pouches but faced a significant operational obstacle.
Their existing labeling system had been built around the dimensions and layout of bags supplied by another vendor. Because hundreds of SKUs were managed using custom stickers, simply switching to a new stock pouch would require redesigning labels, adjusting workflows, and potentially disrupting operations.
- At the same time, they needed:
- High-quality coffee packaging
- Flexible inventory management
- Degassing valves and pocket zipper configurations
- Competitive pricing
- Consistent branding across multiple product lines
Finding a supplier that could accommodate these requirements without forcing major operational changes proved challenging.
The EFP Solution: Flexibility First
Rather than asking the customer to adapt to a standard stock pouch, Enviro Flex Pack developed a custom blank pouch solution tailored to US Roast's existing workflow.
We customized the pouch structure to include:
- One-way degassing valves
- Pocket zippers
- Dimensions compatible with their labeling system
Most importantly, we were able to keep pricing close to traditional stock pouch levels, giving US Roast the flexibility of a custom solution without the typical custom-order cost burden.
Building Trust Through Product Performance
Before committing to a larger custom order, US Roast chose to evaluate Enviro Flex Pack's quality through a smaller purchase of our 5 lb side gusset stock pouches.
This served as a real-world quality test.
After receiving and using the bags, the customer was highly satisfied with the material quality, construction, and overall performance. This initial order established the confidence needed to move forward with a larger custom packaging program.
Expanding the Partnership
After successfully launching the custom blank pouch program, US Roast approached Enviro Flex Pack with a much larger opportunity.
They wanted to transition their existing 12 oz branded coffee bags to EFP while maintaining the premium look and feel their customers already recognized.
At first glance, the request seemed straightforward: reproduce the current packaging as closely as possible.
However, a deeper analysis revealed a more complex situation.
Discovering Hidden Inconsistencies
During our packaging review, Enviro Flex Pack discovered that US Roast's existing packaging system was not as standardized as it appeared.
Across their product line, we found:
- Multiple barrier material structures
- A mix of VMPET and aluminum foil constructions
- Different printing methods across products
- Variations in appearance and finish between bag sizes
While the customer initially requested a 1:1 replication of their current packaging, the reality was that their existing packaging program lacked consistency.
This created an opportunity to improve rather than simply duplicate.
Strategic Packaging Consultation
At this stage, Enviro Flex Pack's role extended far beyond manufacturing.
We worked closely with the customer to evaluate:
Material Selection
Comparing barrier structures, appearance, durability, and shelf-life performance to determine the most appropriate material for long-term brand consistency.
Printing Method Analysis
Evaluating the trade-offs between digital printing and rotogravure printing, including:
- Cost efficiency
- Reorder flexibility
- Color consistency
- Long-term scalability
Color Management
Developing a practical strategy to achieve consistent color reproduction across both 12 oz and 5 lb packaging formats.
Production Optimization
Identifying and resolving potential issues before production, including:
- Valve placement
- Zipper configuration
- Artwork readability
- File preparation requirements
- Print stability considerations
By addressing these details early, we helped reduce risk and improve production outcomes before the bags ever reached the press.
Creating a More Unified Brand
Rather than mechanically reproducing every detail of the existing packaging, Enviro Flex Pack helped US Roast create a more cohesive packaging system.
Our recommendations focused on:
- Standardizing materials across product lines
- Improving visual consistency
- Simplifying future reorders
- Increasing production efficiency
- Maintaining a premium appearance while optimizing costs
The result was a packaging program that looked more consistent, operated more efficiently, and positioned the brand for future growth.
Results
Improved Packaging Quality
US Roast reported that the new packaging delivered stronger color reproduction, improved material feel, and a more premium overall appearance compared to their previous bags.
Greater Brand Consistency
The updated packaging system created a more unified look across multiple product formats and sizes.
Streamlined Future Production
By standardizing materials and printing strategies, future reorders became simpler and more cost-effective.
Expanded Product Portfolio
Following the success of the 12 oz program, US Roast continued developing additional packaging projects with Enviro Flex Pack, including custom 5 lb coffee bags.
Long-Term Partnership
What began as a stock pouch inquiry evolved into an ongoing strategic partnership built on trust, technical expertise, and consistent results.
Customer Outcome
Today, US Roast continues to work with Enviro Flex Pack across multiple packaging programs and has actively recommended EFP to other coffee brands within the industry.
Their endorsement reflects more than satisfaction with a single order—it demonstrates confidence in our ability to solve packaging challenges, optimize production decisions, and support long-term brand growth.
Key Takeaway
Many packaging suppliers can manufacture a bag.
Enviro Flex Pack helps brands build a packaging system.
By combining flexible manufacturing, technical expertise, and strategic consultation, we help coffee roasters make smarter packaging decisions that improve consistency, reduce complexity, and support long-term growth.
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