From 5,000 to 250,000 Coffee Bags: How AT PACK Supported Kitty Town Coffee’s Packaging Growth

The first project was approximately 5,000 custom 12oz flat bottom coffee bags.

Over the next five years, Kitty Town Coffee continued expanding its product lines and sales channels. What started as a single coffee bag project developed into a long-term packaging partnership.
By 2026, one single order reached 250,000 coffee bags, including multiple designs, sizes, and bag styles.

Challenges

As Kitty Town Coffee grew, their packaging requirements became more advanced.

The challenge was no longer only about creating attractive packaging. The coffee bags needed to balance:

• Strong brand presentation
• Reliable freshness protection
• Compatibility with automated filling equipment
• Consistent quality across different sizes and designs

One of the biggest challenges came from the customer’s automated coffee filling process.

During production, machines use suction cups to separate the front and back panels of the bag before filling roasted coffee beans. If the gusset area of the bag sticks together during production, the machine cannot open the bag properly.

This could lead to:

• Filling interruptions
• Production efficiency issues
• Product waste
• Additional manual handling

For large-volume orders, even a small packaging issue could create significant impact on the customer’s production line.

Solution

AT PACK worked closely with Kitty Town Coffee to optimize the packaging based on their actual production environment.

1. Improving Bag Structure for Automated Filling

AT PACK reviewed the bag dimensions, opening size, and structure to improve machine compatibility.

The bag design was adjusted to allow the suction system to separate the front and back panels more smoothly, improving stability during automated filling.

2. Optimizing Material Performance

Based on Kitty Town’s brand positioning and packaging requirements, AT PACK provided suitable high-barrier material solutions.

The packaging evolved from the original:

MOPP / VMPET / PE structure

to upgraded options including:

MOPP / Kraft Paper / VMPET / PE structure

The kraft paper layer improved the natural and premium appearance of the packaging while maintaining strong moisture and oxygen barrier performance.

3. Strengthening Quality Control

To ensure stable performance in real production, AT PACK added additional inspection steps focusing on the gusset area.

Each batch was checked to ensure the bags could open properly and meet the requirements of Kitty Town’s filling process.

Beyond producing bags based on drawings, AT PACK focused on creating packaging that could work reliably in the customer’s daily operations.

4. Expanding into a Complete Packaging Solution

As Kitty Town Coffee continued developing, AT PACK expanded support beyond coffee bags.

The cooperation gradually included:

• Different sizes of coffee bags
• Single-serve coffee packaging
• Custom paper cups
• Plastic cups
• E-commerce shipping bags
• Packaging boxes

AT PACK became a long-term partner helping manage different packaging categories through one supply chain.

Results

After five years of cooperation, Kitty Town Coffee’s packaging journey grew significantly:

• From 5,000 pcs initial orderto 250,000 pcs single order 
• From one 12oz coffee bag to multiple sizes and packaging formats
• From basic customized packaging to a complete brand packaging system

The 2026 order included:

• 100,000 pcs 12oz coffee bags (Design 1)
• 100,000 pcs 12oz coffee bags (Design 2)
• 30,000 pcs 2lb coffee bags
• 20,000 pcs 5lb stand-up coffee bags 
•  

The collaboration between the two parties has evolved from simple packaging procurement into a long-term partnership encompassing packaging development, material optimization, production support, and new product development.

Project Tags