LeapCase Study: Coffee Chain — United States
The Client
National specialty coffee chain, 800+ locations across the US. Annual volume: 50 million hot cups across three sizes (8oz, 12oz, 16oz). Custom 360° printed design with 5-color Pantone-matched artwork. Previous supplier: US-based converter with 28-day lead times and 7.5% defect rate.
The Challenge
Three requirements had to be met simultaneously. Color consistency: 5-color Pantone-matched artwork across 3 production lines and multiple batches — indistinguishable to customers. Registration precision: 360° full-wrap printing on double-wall ripple cups at 180 pcs/min. Supply reliability: 50M units/year required 99.5%+ on-time delivery to prevent stockouts at 800+ locations.
Our Solution
Double-wall ripple cups (240–280 GSM combined) with PE inner coating. 360° flexographic printing with 5 Pantone spot colors. Color matched across 3 dedicated production lines with spectrophotometer verification every 4 hours. Safety stock program: 4 weeks of inventory maintained in Qingdao warehouse with automatic reorder triggers. Sea freight to US West Coast (18–22 days) + rail to Midwest DCs.
Results
- 18% cost reduction per cup — savings of ~$450,000/year
- Defect rate reduced from 7.5% to 0.3% (AQL 1.0 inspection)
- 99.7% on-time delivery rate over 24 months — zero stockouts
- Color consistency ΔE < 2.0 across all production batches
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