Coffee Pod Manufacturing Process and Quality Control

Podding the Coffee

This is where the coffee is formed into the pod in the nitrogen-filled chamber.

Coffee filter paper is fed over the puck-shaped mold, and the ground coffee is dropped into the mold and tamped down. This step determines the size, shape and weight of the pod.

Size is measured in millimeters because the first pod coffee makers were made in Europe.

The shape is determined by the mold. Some pods are flat with a domed top, and some are equally rounded on both sides.

The coffee dropped into the mold is precisely measured. Anywhere from 6 grams to 11 grams of coffee is molded into the pod. A 9-gram pod is required to make a good 8-oz. cup of coffee.

The next step moves the pod forward, and feeds the top filter paper to cover the pod. A cutter and sealer clamps down and heat-seals the pod, and trims the filter paper into the 60mm round shape. Sixty-millimeter pods are considered standard.

A computer controlled robotic arm then grabs the finished pod, and positions it into a folded foil pouch. A small stainless steel probe pumps 99% pure nitrogen gas into the pouch as it is being sealed.

The coffee pod is now complete. The ground coffee has never been exposed to oxygen and will retain its fresh roasted flavor for a year.

Gourmet coffee pods are packaged in finely printed laminated foil/polyester pouches and neatly stacked into a cardboard carton. The cardboard carton will state information about the origin and quality of the coffee and the name of the manufacturer.

Some may ask if the great packaging is necessary. Manufacturers of gourmet coffee pods will proudly tell you that it is necessary. And it only costs about a half a penny per pod more than putting loose pods in a paper sack.

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