Filling Coffee Bags: Efficiency Tips for Small Roasteries and Home Roasters

Sure, bagging efficiently saves time and avoids headaches—but it’s about more than just convenience. If you’re a one-person operation, time is your most valuable asset. Efficiently filling coffee bags frees up time for other aspects of your business, like marketing, shipping, or, of course, roasting more beans! Let’s make that happen, shall we?

A good bag-filling process starts with a thoughtfully designed workspace. Whether you have a cozy home setup or a small roasting operation, an organized layout can save you tons of time.

One strategy to maximize efficiency is to design your space for a circular workflow. Set up your green coffee storage, roaster, and bagging station in a logical, easy-to-follow path, so your beans move through the space like they’re on a conveyor belt (even if they’re not). This helps prevent backtracking or crossing paths with others.

Also, make sure your bag-filling station is at the right height—a tall table will do wonders for your back. If you’re standing on hard floors all day, grab some cushioned mats to avoid strain. Trust us, your future body will thank you.

Want some helpful guidance in planning your space? Mill City Roasters provides a roastery architecture class at each Coffee Fest show. It also dives into the topic on the first day of its Roasting 101 class, assisting students to design hypothetical floorplans.

Now, let’s talk gear. The right tools can turn you into a bagging machine. (Not literally, but close enough.)

Forming Shoes

If you’re not using a forming shoe yet, get ready to meet your new best friend. This simple piece of equipment opens the bag and give it its shape prior to filling. This allows you to avoid sticking your hand or other utensils into the bag.

Plus, it helps create that all-important bottom crease in gusseted bags, ensuring your bags sit nice and sturdy on the shelf. Wooden forming shoes are popular, but we recommend nonporous materials like stainless steel or plastic. They’re better for all things food safety and easier to clean.

Scoops

Not all scoops are created equal! Use food-safe materials like stainless steel or plastic and keep separate scoops for green and roasted beans to avoid cross-contamination. You might not know this, but raw coffee is not considered a food safe product, so keeping things separate is key.

Heat Sealer

Time to seal the deal! A good heat sealer locks in freshness and ensures your bags are tamper-evident. There’s a wide range of heat sealers available on the market—some people even use a straightening iron (yes, like for hair) before deciding to invest in a dedicated heat sealer! If you’re currently using a handheld sealer, consider upgrading to a foot pedal version. It’s safer, gives you better control, and frees up your hands.

Want to take it to the next level? Look into heat sealers with temperature control, which you can tailor to your chosen packaging materials and prevent melted bags or weak seals.

Here’s a quick breakdown of heat sealers that we recommend, ranked from good to best.

• Good:

  • Table Top Impulse Heat Sealer

  • Handheld Heat Sealer

• Better:

  • Foot Operated Heat Sealer

• Best:

  • Continuous Band Sealer: Most effective combined with weigh-and-fill machine. To see it in action, check out Mill City Roaster’s video here.

Speaking of heat sealers, let’s get technical for a minute. The sweet spot for most bag materials is around 120-130°C (248-266 F), but if you’re using kraft paper bags, you might need to dial the temp up a bit. The goal is to find that Goldilocks temperature—not too hot, not too cold—so your bags seal perfectly every time. Play around with your settings, and you’ll find the magic number that works for you.

If you’re looking to extend your coffee’s shelf life, consider nitrogen flushing. It removes oxygen (the sworn enemy of coffee freshness) and replaces it with nitrogen, which helps to extend shelf life and keep your beans tasting their best. While nitrogen flushing doesn’t change the flavor of your beans directly, it preserves that fresh-roasted taste for longer, which is a win in our book. We recommend this company for gas flush sealers.

The key to a smooth bag-filling operation? Keep your equipment in tip-top shape. Your heat sealer and scales work hard, so they deserve a little TLC. Regular calibration is essential for accurate measurements—especially if you’re selling coffee by weight—and a quick clean after each use goes a long way in preventing breakdowns.

Filling coffee bags efficiently is about more than just speeding up the process—it’s about working smarter, not harder. With the right tools, an organized layout, and a little know-how, you can turn a time-consuming task into a breeze.

Whether you’re filling bags for a small business or as a home roasting hobbyist, these tips will help you stay productive, keep your operation running smoothly, and, most importantly, keep those beans ready for your customers or your own morning brew.

Go ahead—bag those beans like a pro and watch your efficiency soar! Need a packaging partner to help you up your game? We’re glad you asked. Take our Product Finder quiz to get matched with your packaging soulmate and take the next step in your roasting journey!