How Ferris Coffee Scaled Cold Brew Distribution with Eco-Friendly PET Kegs

Founded in 1924, Ferris Coffee is a family-owned business based in Michigan with nearly a century of experience in sourcing and crafting exceptional coffees. The company is committed not only to perfecting its beverage offerings but also to enhancing its environmental footprint. As part of its ongoing commitment to sustainability in the competitive cold brew market, Ferris Coffee sought a more cost-effective, eco-friendly packaging alternative to stainless steel kegs for serving cold brew on tap.

In April 2018, Ferris embraced Petainer’s 20L one-way PET Hybrid Kegs, enabling them to expand distribution beyond their own cafés while maintaining the quality and taste that their customers expect.

The Challenge: High Costs, Sustainability & Customer Experience

Before adopting the new packaging solution, Ferris Coffee faced several challenges typical of cold brew distribution. The company needed to address the high capital investment required for stainless steel kegs, along with the logistical and environmental drawbacks of managing a return system and water-intensive cleaning processes.

Additionally, maintaining the fresh taste and quality of their cold brew was essential for preserving their brand reputation. Specifically, Ferris needed to:

• Lower Costs & Easier Market Entry: The traditional model required significant upfront expenditure on a fleet of steel kegs and the accompanying washing and return logistics, which was unsustainable for a growing, smaller operation.
• Enhance Sustainability: Reducing water usage, chemical cleaning agents, and greenhouse gas emissions was crucial for a company committed to eco-friendly practices.
• Ensure Customer-Friendly Experience: The solution had to keep the cold brew fresh and flavorful while being easy for clients to use and dispose of, thereby supporting the company’s reputation for quality.

The Solution: Petainer’s One-Way Hybrid Kegs

To overcome these hurdles, Ferris Coffee transitioned to using Petainer’s 20L one-way PET Hybrid Kegs for distributing cold brew outside their cafés. This innovative solution provided a seamless way to deliver high-quality, fresh-tasting cold brew while reducing operational costs and environmental impact. Key features of the solution include:

• No Return Logistics: The one-way design means there is no need to retrieve empty kegs, eliminating the expenses and complexity of managing a return system.
• Lower Environmental Impact: Because the kegs arrive sanitized, no hot water or harsh chemicals are required for cleaning—significantly reducing energy usage and overall ecological footprint.
• Enhanced Product Protection: The high-quality PET material protects against off-flavors and preserves the delicate taste of carefully sourced beans.
• Scalable to New Markets: The flexible, low-capex nature of hybrid kegs allows Ferris to test and expand into new regions without a large upfront investment.

Results: Eliminating Steel Keg Cleaning Process

The implementation of Petainer’s one-way PET kegs has delivered significant benefits for Ferris Coffee. By eliminating the need for stainless steel kegs and the associated cleaning processes, Ferris has streamlined its operations and reduced both capital and operational costs. Key outcomes include:

• Reduced Capital Expenditure: Freed from investing heavily in steel kegs and sanitation equipment, Ferris can now allocate resources to other areas such as product innovation and brand development.
• Lower Shipping & Storage Costs: The lightweight nature of PET kegs reduces shipping expenses and minimizes storage requirements, contributing to a lower carbon footprint.
• Improved Customer Experience: Customers enjoy consistently fresh, high-quality cold brew, which has helped bolster the brand’s reputation in the market.

One-way PET kegs are a really easy option and support the growth plans of smaller businesses like ours by lowering the cost of entry into new markets—cold brew coffee is a big new trend we want to capitalize on. Crucially, the feedback from our customers has been really positive. They find Petainer kegs easy to use and to dispose of. If our customers are happy, we’re happy.

Sam Mirto, Director of Coffee at Ferris Coffee

Conclusion: A Future of Sustainable Cold Brew Growth

Ferris Coffee’s adoption of Petainer’s one-way Hybrid PET Kegs exemplifies how a well-chosen packaging solution can strengthen a company’s commitment to sustainability while unlocking new growth opportunities. By eliminating the need for a costly steel keg system and its associated logistical challenges, Ferris has been able to confidently expand its distribution network and enhance its market presence—all while preserving the fresh, exceptional quality of its cold brew.

This success story illustrates that even time-honored brands can lead the way in innovative, eco-friendly practices.