Columbus, Ohio – BrootLegg Extracts, a burgeoning Columbus-based beverage technology company, has officially launched its innovative business-to-business cold brew production services, underpinned by a proprietary high-pressure extraction system. This groundbreaking technology, developed in-house, not only enables significantly faster and more efficient cold brew creation but also powers the company’s own line of ready-to-drink (RTD) bottled cold brews, offering a unique blend of technological advancement and artisanal quality. The company’s strategic entry into the market marks a significant development in the cold brew industry, promising enhanced scalability and consistency for beverage producers.
The Science Behind the Brew: High-Pressure Extraction
At the core of BrootLegg Extracts’ innovation lies a sophisticated brewing system inspired by the principles of commercial espresso machinery. This system employs a unique approach, forcing water through a sealed stainless steel canister at pressures reaching up to 1,200 psi (approximately 82.7 bar). This pressure is more than nine times that of a standard 9-bar espresso extraction, a level of force rarely, if ever, applied in traditional cold brew methods. While primarily engineered for cold-water extraction, the BrootLegg system offers remarkable versatility, allowing for an optional hot bloom phase, along with precise adjustments to brew ratio, temperature, and pressure.
The physical footprint of the BrootLegg machine is comparable to an upright coffee shop batch brewer. Its design features a robust base that houses the essential components: a high-performance pump, a network of precision valves, a heating system for temperature control, and sophisticated electronics for managing the brewing process. Above this base sits the heart of the operation – the stainless steel extraction canister, meticulously engineered to withstand the immense pressures involved. This canister is designed to hold only the coffee grounds or other extraction mediums, functioning akin to an oversized, heavy-duty portafilter found on high-end espresso machines.
Operational Efficiency and Scalability
BrootLegg Extracts currently operates multiple machines within its expansive 5,000-square-foot production facility located in Columbus’s Merion Village neighborhood. These machines are capable of producing five gallons of ready-to-drink cold brew in a remarkably short 45-minute cycle. A key efficiency metric highlighted by the company is its low coffee-to-water ratio, utilizing only 2 to 3.5 pounds of coffee per five-gallon batch. This contrasts sharply with traditional immersion cold brewing methods, which often require significantly longer brew times, larger physical spaces, and the use of disposable filtration materials.
The company emphasizes the "infinitely scalable" nature of its technology. Co-founder Colin Giacalone explained, "Vessel size and vessel quantity can increase without jeopardizing the quality of the liquid product. Increasing the size of the vessel will increase the liquid yield while keeping the brewing time the exact same." This modular design allows for significant expansion of production capacity. BrootLegg anticipates being able to produce approximately 100 gallons of product in a single batch, catering to a wide spectrum of desired beverage profiles, from RTD cold brew at a total dissolved solids (TDS) of 1.8% to highly concentrated extracts at 8% TDS.
A Journey of Innovation: From Basement Lab to Production Facility
The development of BrootLegg’s revolutionary brewing system is the culmination of a multi-year journey driven by a unique blend of expertise. The founding team comprises Colin Giacalone, with a background in chemical engineering; Willy Kramer, whose experience spans welding and expert barista work; and Chadwick Carter, a software engineer.
The genesis of BrootLegg dates back to 2017 when Giacalone and Kramer, then colleagues at a Columbus coffee shop, began to view the cafe’s existing cold brew process as an engineering challenge. Their shared passion for coffee and problem-solving led them to explore alternative extraction methods. Two years later, Chadwick Carter joined their endeavor, transforming Kramer’s basement into a makeshift laboratory. This space was significantly retrofitted to handle higher voltages, with custom plumbing and even a blast shield installed "in case anything went sideways," a testament to the experimental nature of their early work.
Carter’s initial contribution focused on programming automated valve sequences. "The first thing I worked on was programming the valve turns so none of us had to walk out and depressurize the first system," he shared. This early focus on automation and safety was crucial for the development of a robust and reliable system.
By 2021, the trio was ready to test their innovations on a larger scale. They began sharing samples with Jeff Davis, owner of Brioso Coffee, a respected local roaster. This collaboration proved pivotal. A BrootLegg machine was installed in the backroom of Brioso’s roastery-cafe, serving as a testing ground for further research and development while simultaneously producing cold brew for the shop. This real-world application provided invaluable feedback and refined the technology.
The company secured its first U.S. patent for the brewing system in 2022, a significant milestone that validated their novel approach. Following this success, the BrootLegg founders secured equity financing from a group of local investors, enabling them to establish their dedicated production warehouse in Columbus’s Merion Village. By late 2023, the facility was fully operational, and BrootLegg Extracts officially launched its commercial services.
Market Impact and Partnership
BrootLegg Extracts is currently supplying its cold brew and concentrate to over 120 businesses across Central Ohio, including coffee shops, bars, restaurants, and offices. The company also markets its own branded line of RTD bottled cold brews, which prominently feature coffees roasted by their early collaborator, Brioso Coffee. This dual approach allows BrootLegg to showcase its production capabilities while also building its own consumer brand.
"One of the things that we love about coffee is how many people do an awesome job of making it," Kramer remarked. "We pride ourselves on the fact that we can make products with any bean, supporting shops and businesses of all sizes with products they can call their own." This commitment to supporting other businesses underscores BrootLegg’s B2B focus and its role as an enabler within the coffee industry.
To further amplify its production capabilities and ensure widespread availability of its brewing systems, BrootLegg Extracts has entered into a strategic partnership with Grote Company, a renowned Columbus-based manufacturer of commercial kitchen equipment. This collaboration is designed to scale the manufacturing of BrootLegg’s innovative brewing systems. "It’s so cool to see someone else make one of our pieces of technology," Kramer expressed. "We’re excited to explore how we could further distribute our goods and service, as well as the equipment, to the coffee industry."
Implications for the Beverage Industry
The introduction of BrootLegg Extracts’ high-pressure cold brew technology presents several significant implications for the broader beverage industry. Firstly, the drastically reduced brewing time challenges the conventional wisdom that high-quality cold brew requires extended steeping periods. This efficiency gain translates directly into operational cost savings for businesses, allowing for faster inventory turnover and reduced labor.
Secondly, the elimination of disposable filtration media aligns with growing industry and consumer demand for sustainable practices. Traditional cold brew methods often generate substantial waste from filters, a concern that BrootLegg’s closed-system approach effectively mitigates.
Thirdly, the system’s inherent scalability offers a compelling solution for businesses experiencing rapid growth. The ability to expand production capacity without compromising brew time or quality provides a significant competitive advantage, particularly for large-scale distributors and national chains. The precise control over brewing parameters also ensures a higher degree of consistency across batches, a critical factor for brand integrity and customer satisfaction.
Finally, BrootLegg’s model of offering production services alongside equipment sales provides a flexible entry point for various businesses. Smaller cafes can leverage BrootLegg’s expertise and infrastructure for their cold brew needs without the capital investment in specialized equipment, while larger operations can integrate the technology directly into their facilities. This versatility positions BrootLegg Extracts as a potentially transformative player in the evolving landscape of beverage production.
The company’s journey, from a concept born in a coffee shop to a patented, scalable technology supported by industry partnerships, exemplifies entrepreneurial drive and technical innovation. As BrootLegg Extracts continues to expand its reach and influence, its high-pressure extraction method is poised to redefine efficiency, quality, and sustainability in the world of cold brew and beyond.
