Nestlé Develops New Freeze-Drying Technology to Eliminate Clumping in Cold Coffee

As global demand for cold coffee continues to rise, Nestlé has introduced an innovative freeze-drying process that significantly improves the solubility of instant coffee in cold liquids, solving one of the biggest challenges in the cold coffee segment: clumping.

This breakthrough comes as the global iced coffee market surges toward an estimated value of $16.8 billion by 2033, up from $9.8 billion in 2025, according to market research data. In the U.S. alone, 42% of consumers reported drinking cold coffee at least once a week in 2023—up from 30% in 2020—highlighting a major shift in consumer preferences.

What is Nestlé’s new cold coffee freeze-drying innovation?

Nestlé’s R&D team at the Nescafé Product Technology Center in Orbe, Switzerland, adapted traditional freeze-drying (lyophilization) methods—commonly used for hot instant coffee—to suit cold applications. The modified process involves brewing coffee, freezing it at –40°C, and using sublimation in a vacuum chamber to remove moisture without damaging flavor or aroma.

While conventional freeze-drying creates premium-quality coffee for hot use, it struggles with clumping and uneven taste in cold liquids. Nestlé’s optimized version solves this by:

• Enhancing solubility in cold water

• Preserving flavor profile consistency

• Creating a smoother drinking experience

“Consumers of cold coffee expect great taste and convenience. This innovation allows us to deliver both,” said Siobhan Gaudino, Head of R&D for Coffee at Nestlé.

The improved process was first introduced in Japan in 2023 with the launch of Nescafé Iced Blend, marking a major milestone in Nestlé’s cold coffee strategy.

Why is this innovation important for the cold coffee market?

Cold coffee is one of the fastest-growing beverage segments globally. Consumers—especially younger generations—are looking for versatility, texture, and café-style experiences at home.

Nestlé’s innovation addresses several market needs:

• Improved solubility for instant iced coffee

• Scalability for business-to-business use

• Compatibility with emerging trends in health, texture, and flavor customization

How does Nestlé ensure cold coffee quality?

Nestlé uses a bean-to-blend approach, optimizing every stage of coffee development:

• Bean selection: High-yield varieties bred for climate resilience

• Roasting & brewing: Tailored profiles from fruity blondes to smoky dark roasts

• Freeze-drying enhancements: Customized for cold solubility and foam creation

• Aroma protection: Proprietary steam treatments to preserve freshness

The company also focuses on sensory science, using consumer testing and quality assurance to ensure consistency across instant mixes, capsules, and ready-to-drink formats.

New product launches reflect growing consumer demand

To capture growing market share, Nestlé is expanding its cold coffee product lines, including:

• Starbucks Crema Collection: Delivers a rich foam layer (crema) in instant coffee

• Nespresso Boost range: High-caffeine blends (200 mg per cup) for health-conscious users

• Nescafé Espresso Concentrate: A liquid base for barista-style iced coffee at home

Launched recently in Australia and China, the espresso concentrate allows consumers to create personalized cold coffee beverages and is one of Nestlé’s top six global innovation initiatives.

Key Takeaways :

• What did Nestlé develop? A new freeze-drying method that prevents clumping in cold coffee.

• Why is it important? It improves taste and solubility, addressing a major challenge in the iced coffee segment.

• When was it launched? First released in Japan in 2023 with Nescafé Iced Blend.

• How does it work? Through an optimized freeze-drying process that adapts to cold applications.

• What’s next? Global expansion of cold coffee innovations, including espresso concentrates and functional blends.

Cold Coffee Market Forecast:

• Global value in 2025: $9.8 billion

• Expected value by 2033: $16.8 billion

• U.S. cold coffee drinkers in 2023: 42% of the population