What Roastar does

Roastar is a US-based, privately held custom-printed packaging manufacturer founded in 2015 and headquartered in Wausau, Wisconsin. The company produces digitally printed flexible packaging — flat bottom bags, stand up pouches, gusset bags, flat pouches, paper tin tie bags — alongside rigid formats including tin cans and paper tubes, plus rollstock, labels, stickers, and paper mailers. Its core technology differentiator is digital printing, which eliminates plates and tooling charges and supports minimum order quantities as low as 500–1,000 units for custom runs and 1 unit for Design Lab personalization, materially below the 5,000+ unit minimums typical of flexographic printers. Specialty features include one-way degassing valves for fresh coffee packaging and a Wrapped Collection Program partnering with Trex to recycle bags into composite decking.

The business operates a direct-to-customer e-commerce model with instant online quoting, self-service ordering, and an online design platform (Roastar Design Lab) featuring generative AI design tools. Revenue is transactional and unit-priced across product lines, with shipping scaled by order quantity. The primary customer base consists of small-to-medium specialty coffee and tea roasters, with secondary expansion into pet food and treats, artisan foods and snacks, spices, candy and chocolate, supplements, and child-resistant packaging use cases. Named reference customers are predominantly SMB coffee roasters (e.g., Berres Brothers, Equator Coffees, Trident Coffee Roasters, Henry's House of Coffee) alongside mid-market beverage brands such as Rishi Tea. Distribution combines product-led growth (Design Lab, free sample packs) with an inside sales team available via a toll-free line for B2B quoting and account management, plus a Designer Network and trade show participation for community engagement.

Roastar does not disclose revenue, funding, or headcount; the company is independently owned with no institutional investors disclosed. Operational capabilities indicate a small, vertically integrated print operation with a US-based manufacturing footprint, and its value proposition centers on compressing traditional print lead times (days rather than weeks), removing setup fees, and enabling low-volume custom branding for emerging CPG brands.

Name

Roastar

Legal name

Roastar, Inc.

Website

https://roastar.com

Company type

Private

Founded year

2015

Operating status

Operating

Headcount range

101–250 employees

Short description

Roastar is a US-based custom-printed packaging manufacturer serving primarily small-to-medium coffee and tea roasters with digitally printed bags, pouches, tin cans, paper tubes, and labels through a self-service e-commerce platform with low minimum order quantities and online design tools.

Ownership category

akta.pro rank

Product category

Custom Flexible Packaging

NAICS

Paperboard Container Manufacturing (32221)

SIC

Plastics, Foil & Coated Paper Bags (2673)

akta.pro primary industry

Flexible Packaging Printing (Film/Poly/Paper Print) (IMALAKAG)

akta.pro secondary industry

Secondary & Multipack Packaging (IMALAHAB)

Keywords

• Custom flexible packaging
• Digital printing packaging
• Custom coffee bags
• Stand up pouches
• Specialty food packaging

Headquarters

HQ city

Wausau

HQ country

United States

HQ region

North America

Offices1 record

Markets served

GTM type

B2B

Offering type

Hardware or Manufacturing

Cost components

Supply Chain, Personnel, Operations, Technology or R&D, Marketing or Sales, Infrastructure

Revenue model

1. Custom-Printed Packaging Sales: Primary revenue stream from custom-printed bags, pouches, tin cans, paper tubes, and other packaging products. Customers can order fully customized packaging with their own designs. Pricing varies by product type, quantity, and material selection.
2. Stock/Blank Packaging Sales: Pre-manufactured blank packaging products ready to ship within 24-48 hours. Includes bags, pouches, tin cans, paper tubes, stickers, and accessories. Lower unit costs at higher volumes.
3. Design Lab Products: Pre-designed patterns available through Roastar Design Lab with personalization options. Products include gusset bags, flat bottom bags, stand up pouches, tin cans, and labels at reduced minimums starting at 1 unit.
4. Shipping Services: Shipping fees based on volume (quantity-based tiers from $25 to $300) or weight/destination for certain products. Free shipping for sample packs and sticker orders.

Pricing tiers

Go-to-market motion3 records

Distribution channels3 records

Marketing channels7 records

Core offering

Roastar manufactures and sells custom-printed flexible packaging — including flat bottom bags, stand up pouches, gusset bags, flat pouches, paper tin tie bags, tin cans, and paper tubes — using digital printing technology that eliminates plate fees and setup charges. They also offer stock/blank packaging, custom labels and stickers, and an online design platform (Roastar Design Lab) with AI tools and minimum order quantities as low as 1 unit.

Product overview

Roastar is a custom-printed packaging company offering a comprehensive portfolio of flexible packaging solutions primarily serving the specialty food and beverage industry, particularly coffee roasters. The product line centers on digital printing of bags and pouches (flat bottom bags, stand up pouches, gusset bags, flat pouches, paper tin tie bags), rigid containers (tin cans, paper tubes), labels and stickers (coffee bag labels, brand stickers, beverage labels), and shipping solutions (paper mailers, shipping cartons). The company operates Roastar Design Lab as an online design platform enabling customers to create personalized packaging with AI-powered tools and ultra-low minimums. Roastar differentiates through digital printing technology (eliminating plate fees and setup charges), USA-based manufacturing in Wausau, WI, industry-leading turnaround times, and sustainability initiatives including compostable, recyclable, and biodegradable material options plus the Wrapped Collection Program for bag recycling.

Differentiator

Problem solved

Functional benefit

Brands

• Roastar Design Lab: Online design tool for creating personalized packaging with ready-to-use patterns and AI capabilities
• Wrapped

Products and services

• Flat Bottom Bags Custom-printed or blank flat bottom bags offering maximum shelf stability and five-sided branding canvas for coffee, chocolate, pet treats, and dry food products. Min order 1,000 units (1,000 per design).
• Stand Up Pouches Custom-printed or blank stand up pouches with gusseted bottom for strength and rectangular profile that stands out on retail shelves, suitable for dry, liquid, or powdered products. Min order 1,000 units (100 per design).
• Gusset Bags Custom-printed or blank gusseted bags, the most common coffee specialty packaging style with impressive volume and shelf stability, pairable with tin ties. Min order 500 units (100 per design).
• Flat Pouches Custom-printed or blank flat pouches serving as economical solutions for single-servings or samples, available with hang holes and tear notches.
• Paper Tin Tie Bags Custom-printed or blank kraft paper bags with tin tie closures for a classic, space-efficient resealing approach popular in food packaging.
• Tin Cans Custom-printed or blank tin cans in straight or beaded varieties, offering 100% curbside recyclability and the longest freshness preservation of any Roastar offering. Min order 50 units (10 per design).
• Paper Tubes Custom-printed or blank rigid two-piece paper tubes that are 100% recyclable with biodegradable liner bags, offering a sustainable packaging solution.
• Rollstock Custom-printed roll stock packaging for brands seeking efficiency and flexibility to package products on demand with style and speed.
• Paper Mailers Custom-printed or blank paper mailers for shipping products, available in various sizes with custom branding options.
• Coffee Bag Labels Custom-printed labels designed to wrap around coffee bags, spreading brand awareness and providing product information on blank or existing packaging.
• Brand Stickers Custom-printed brand stickers for spreading brand awareness and adding promotional elements to products and packaging.
• Beverage Labels Custom-printed beverage labels for ready-to-drink products, allowing brands to create distinctive packaging for cold brew, teas, and other beverages.
• Roastar Design Lab Online packaging design platform enabling customers to create personalized packaging using ready-to-use patterns, AI-powered design tools, and low minimum order quantities as few as 1 unit.
• Wrapped Collection Program Sustainability initiative enabling retail stores to collect and return Roastar's store drop-off recyclable bags for recycling into composite decking through partner Trex, with free collection boxes for orders of 5,000+ recyclable bags.

Quantifiable outcome

• Turnaround times measured in days, not weeks
• +3 more outcomes

Named customers16 records

Segments8 records

Ideal customer profiles2 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

AI capability1 record

Feature5 records

Partnerships

Four partnerships are on record, tiered core and minor.

• TrexcoreStrategic or Co-development PartnerRecycling partnership for the Wrapped bag collection program. Collected recyclable bags from customers are sent to Trex, which transforms them into durable composite decking made from up to 95% recycled and reclaimed materials. This partnership enables Roastar to offer end-of-life recycling for their store drop-off recyclable packaging.
• Roast! West CoastminorGTM or Marketing PartnerMarketing and promotional partnership announced in blog post 'Roastar Partners with Roast! West Coast'. Collaboration to support the specialty coffee community on the West Coast.
• Wausau WoodchucksminorGTM or Marketing PartnerPartnership with local baseball team for sustainability initiative. Blog post 'How Roastar and the Wausau Woodchucks Teamed Up for a More Sustainable Stadium Experience' describes collaborative sustainability efforts.
• Tell Designs (Laura Spaeth)coreImplementation/ SI/ Consulting PartnerPreferred design partner providing packaging design services to Roastar customers. Laura Spaeth worked in Roastar's pre-press department for years before founding Tell Designs in 2018, creating bag artwork full-time. Her deep understanding of the Roastar process makes her extremely skilled at crafting perfect bag designs.

Scale indicators3 records

Recent moves5 records

Expansion highlights5 records

Direct peers

• Lumi: Online platform for custom printed packaging, labels, and inserts serving SMB CPG and e-commerce brands. Same custom-packaging, online-design-tool, SMB wedge as Roastar.
• Packlane: Custom-printed boxes and packaging for SMB and DTC brands via an online design and quoting platform. Closest direct competitor to Roastar's Design Lab motion in custom packaging.
• Sticker Mule: Custom-printed stickers and labels sold through a fully self-serve e-commerce platform with instant quoting and ultra-fast turnaround. Same PLG, instant-quote, SMB-target model as Roastar.
• BoxGenie: Custom-printed boxes and packaging with low MOQs and an online design experience. Overlaps with Roastar's custom-printed mailers, cartons, and accessory packaging.
• EcoEnclose: Sustainable custom packaging supplier (mailers, boxes, labels, tape) for eco-focused SMBs. Closest competitor on the sustainability / Wrapped-style value proposition.
• Arka: Custom packaging and printed products (boxes, mailers, labels) for e-commerce SMBs with online design tools. Competes head-to-head with Roastar's custom-printed packaging line.
• Noissue: Custom sustainable packaging (mailers, boxes, tissue) targeting small CPG brands with low MOQs and an online design tool — directly comparable to Roastar's product-led custom packaging offering.
• Hero Packaging: Compostable and sustainable custom mailers and packaging for SMB brands. Comparable on low-MOQ custom sustainable packaging for CPG customers.

Broad incumbents

• Moo: Established custom print brand (business cards, packaging, marketing materials) selling through a polished e-commerce platform to SMBs. Comparable SMB-focused online custom print model at larger scale.
• Amcor: Global flexible and rigid packaging incumbent serving CPG at scale, including coffee, pet food, and snacks — Roastar's core verticals. Represents the consolidator/exit path or competitive threat from large converters.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat4 records

Key risks6 records

Key highlights6 records

Customer concentration

• Xx.com/RoastarBags

Revenue estimate

Valuation estimate

Number of profiles

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about Roastar