Sponsored by PRO Engineering / Manufacturing Inc. 

Table of Contents 

1. Introduction

2. Market Size & Revenue Outlook

3. Why Pasteurization Is Critical for Coffee Alternatives

4. Yerba Mate: Clean Energy, Complex Processing

5. Cascara: Monetizing the Coffee Fruit

6. Energy Infusions: Botanicals and Functional Caffeine

7. Tunnel vs. Batch Pasteurization

8. Why Beverage Brands Partner with PRO Engineering

9. FAQs

10. Conclusion

1. Introduction

Consumers want caffeine—but not the drawbacks of traditional coffee. Acid sensitivity, energy crashes, and digestive discomfort are driving demand toward yerba mate, cascara, and botanical energy infusions. 

These beverages promise smoother energy and functional benefits, but they also introduce serious food-safety and shelf-life challenges. Unlike roasted coffee, plant-based caffeine drinks contain raw botanicals, fruit material, and sugars that require precise pasteurization to remain commercially viable. 

This is where properly engineered tunnel and batch pasteurization systems become essential. 

2. Market Size & Revenue Outlook

The numbers explain why this category is exploding: 

• Global functional & caffeinated beverage market (2024): ~$140B 

• Projected market by 2030: ~$210B 

• Coffee-alternative CAGR: ~8–10% 

Market Share Breakdown 

• Yerba mate & herbal caffeine drinks: ~18% 

• Cascara beverages: ~6% (early-stage, high growth) 

• Botanical & functional energy infusions: ~22% 

• Traditional energy drinks & hybrids: ~54% 

Retailers are increasingly demanding pasteurized, shelf-stable formats, especially for national and export distribution. 

3. Why Pasteurization Is Critical for Coffee Alternatives

Alternative caffeine beverages face risks that coffee doesn’t: 

• Microbial contamination from leaves, fruits, and roots 

• Fermentation caused by residual sugars 

• Inconsistent shelf life across batches 

Pasteurization solves these issues by: 

• Eliminating harmful pathogens 

• Stabilizing flavor and appearance 

• Extending self-life for retail and distribution 

Manufacturers relying on engineered tunnel pasteurizers or precision batch pasteurization systems dramatically reduce spoilage, recalls, and rejected shipments. 

4. Yerba Mate: Clean Energy Meets Processing Challenges

Yerba mate delivers caffeine alongside antioxidants and amino acids—but its leaf-based origin introduces microbial load and heat sensitivity. 

Key challenges include: 

• Flavor degradation from over-heating 

• Clouding and sedimentation 

• Inconsistent shelf stability 

For large-scale production, continuous tunnel pasteurization allows gradual heating and cooling, preserving flavor while ensuring safety. Many national brands rely on tunnel pasteurizer systems engineered specifically for plant-based beverages rather than generic equipment. 

5. Cascara: Turning Coffee Waste Into Revenue

Cascara beverages convert discarded coffee fruit into a sustainable, high-margin caffeine product. But fruit-based drinks are notoriously unstable. 

Risks include: 

• Yeast growth from natural sugars 

• Batch-to-batch inconsistency 

• Short shelf life without thermal processing 

For emerging cascara brands, batch pasteurization offers flexibility and control. Many startups begin with pilot-scale batch pasteurizers before expanding into tunnel systems as demand grows. 

Learn more about batch-based beverage processing at 
https://prowm.com/batch-pasteurizers-2/ 

6. Energy Infusions: Botanicals, Adaptogens & Functional Caffeine

Energy infusions combine caffeine with ingredients like guayusa, ginseng, green tea extract, vitamins, and nootropics. These formulations are powerful—but fragile. 

Pasteurization challenges include: 

• Ingredient separation 

• Heat-sensitive actives 

• Regulatory compliance for functional claims 

Manufacturers increasingly rely on multi-temperature batch pasteurization or multi-zone tunnel pasteurizers to preserve efficacy while ensuring safety. Advanced systems such as triple-temperature batch pasteurizers allow fine-tuned control for complex formulations. 

7. Tunnel vs. Batch Pasteurization

Tunnel Pasteurization (Best for Scale) 

Ideal for: 

• High-volume production 

• Bottled and canned beverages 

• National and export markets 

Benefits: 

• Continuous flow 

• Consistent pasteurization units (PU) 

• Superior quality control 

Many fast-growing beverage brands transition to large-scale tunnel pasteurizers once distribution expands beyond regional markets. 
https://prowm.com/tunnel-pasteurizers/large/ 

Batch Pasteurization (Best for Flexibility) 

Ideal for: 

• Small to mid-sized producers 

• Seasonal or limited runs 

• R&D and formulation testing 

Benefits: 

• Lower upfront investment 

• Custom time-temperature profiles 

• Ideal for new product launches 

Batch systems provide a practical entry point before scaling into continuous production. 

8. Why Beverage Brands Partner with PRO Engineering

PRO Engineering / Manufacturing Inc. designs pasteurization systems specifically for beverage producers, not one-size-fits-all solutions. 

Their expertise includes: 

• Custom tunnel pasteurizers for plant-based drinks 

• Compact SlimLine tunnel pasteurizers for space-constrained facilities 

• Batch systems engineered for ingredient-sensitive beverages 

Explore PRO’s beverage pasteurization solutions at 
https://prowm.com/ 

9. Frequently Asked Questions

Does pasteurization reduce caffeine levels? 
No. Proper thermal processing preserves caffeine content. 

Is HPP better than thermal pasteurization? 
HPP is expensive and limits packaging options. Thermal pasteurization remains the most scalable solution. 

What shelf life can be expected? 
Typically 6–12 months depending on formulation and packaging. 

Can functional ingredients survive pasteurization? 
Yes, when systems are engineered for precise control. 

When should brands upgrade from batch to tunnel systems? 
Usually when scaling beyond regional distribution or entering export markets. 
 
What is yerba mate and how does it compare to coffee? 
Yerba mate is a traditional herbal infusion made from the leaves of the Ilex paraguariensis plant. It contains natural caffeine and is often used as a coffee substitute for a smoother energy lift with fewer jitters and crashes. (V3 Apparel) 

Is yerba mate safe to drink every day? 
For most adults, moderate yerba mate consumption appears safe. However, very large amounts over long periods — especially at very hot temperatures — may carry some health risks, so it’s wise to consume it in moderation and consult a healthcare provider if you have concerns. (Mayo Clinic) 

What is pasteurization and why is it used in beverages? 
Pasteurization is a heat-treatment process designed to kill or deactivate harmful microorganisms, reduce spoilage, and extend shelf life without significantly altering taste or nutritional quality. It’s widely used across beverage production. (jenrey.ca) 

Does pasteurization affect caffeine or other functional ingredients? 
Pasteurization is essential for safety and shelf life, but it can impact on some heat-sensitive ingredients such as certain vitamins or probiotics. Caffeine and many antioxidants typically remain stable during proper pasteurization. (cascadiafoodbev.com) 

How does pasteurization make beverages safer? 
By heating products to specific temperatures for controlled times, pasteurization reduces harmful microorganisms that can cause foodborne illness, improve consistency, and help beverages remain stable during storage and distribution. (Center for Research on Ingredient Safety) 

10. Conclusion: Turning Coffee Alternatives Into Long-Term Revenue

Caffeinated alternatives to coffee are no longer niche, they’re reshaping the beverage industry. But brands that ignore pasteurization strategy risk spoilage, recalls, and stalled growth. 

By investing in engineered tunnel and batch pasteurization systems, manufacturers can protect product integrity, meet regulatory standards, and confidently scale. 

Partner with a PRO! 

That partner is PRO Engineering / Manufacturing Inc. With over 40 years of experience designing and building custom tunnel and batch pasteurization systems, PRO brings world-class engineering right into your production floor. When you Partner with a PRO, you gain access to: 

• Equipment engineered for your beverage’s specific formulation 

• Systems that protect flavor, color, and shelf stability 

• Hands-on support from installation through optimization 

• Options that scale with your business 

📞 Call PRO today: 414-362-1500 (PRO) 
✉️ Email: [email protected] (PRO) 
📍 Address: 11175 W. Heather Avenue, Milwaukee, WI 53224 USA (PRO) 

Whether you’re launching a new SKU or scaling national distribution, it’s time to Partner with a PRO and elevate your beverage quality and reliability. 

 
REFERENCES: 

Government Links 

https://www.fda.gov/food 
https://www.usda.gov/topics/food-and-nutrition 
https://www.cdc.gov/food-safety 

Wikipedia Links 

https://en.wikipedia.org/wiki/Pasteurization 
https://en.wikipedia.org/wiki/Yerba_mate 
https://en.wikipedia.org/wiki/Energy_drink 

ABOUT PRO ENGINEERING / MANUFACTURING INC.

Trusted | Knowledge | Quality

We have been involved in pasteurizers since 1977.

PRO Engineering / Manufacturing Inc. has developed a range of small, medium, and large-sized tunnel & batch pasteurizers to fit the needs of BrewMasters and Beverage Makers. When our customers asked for more compact as well as full-size tunnel pasteurizers, PRO developed models to fit our customers’ needs. Then our customers needed a batch pasteurizer. We now provide batch pasteurizers; PRO is a business that continually innovates to meet customer needs.

For more than 40 years, we have been delivering solutions for beverage product shelf stability and consumption safety.

Edward A. Michalski CEO

Ed Michalski started his career in the beverage industry by designing stainless steel, higher flow, spray headers for Pabst Brewing. Along with the header design he also developed a process to produce the new headers.

Ed, along with his brother David, formed PRO Engineering / Manufacturing Inc. Based on what they learned by re-designing and refurbishing other manufacturers’ pasteurizers, Ed and PRO started to offer the pasteurizer marketplace superior new pasteurizers. PRO Engineering / Manufacturing Inc. has been designing and manufacturing great pasteurizers for over four decades.

For more information on tunnel and batch pasteurization contact PRO Engineering / Manufacturing, Inc. at [email protected] or call (414) 362-1500 and ask for Ed Michalski, CEO.

Partner with a PRO!… PRO Engineering / Manufacturing Inc.