1. Client Background
Our client, Starbucks, is a globally recognized coffee brand operating thousands of stores across multiple countries and regions.
With strong brand influence in both beverages and merchandise, Starbucks maintains extremely high standards for product quality, safety, and innovation. Its supplier selection process is widely regarded as an industry benchmark, emphasizing ethical sourcing and long-term partnership capabilities.
2. Project Background
In 2017, our team visited Starbucks headquarters in Seattle to explore potential collaboration opportunities.
At the time, Starbucks already had over 20 suppliers, and its supply chain was well established. The key requirement for new suppliers was clear:
Deliver differentiated and innovative solutions.
Although we had previously developed hundreds of ceramic samples, we struggled to secure significant orders due to a lack of differentiation.
A turning point came when Starbucks faced a major safety issue with its double-wall ceramic cups, including:
- Inner wall collision risks
- Structural fragility
- Potential leakage and safety hazards
This led to an urgent product recall across North America, creating an immediate need for a reliable and innovative supplier.
3. Key Challenges
Starbucks set four strict requirements:
1. Maintain Original Appearance
The external design and dimensions had to remain unchanged to ensure consistency in retail display and user experience.
2. Increase Capacity
Upgrade from 10oz to 12oz without changing the external size.
3. Eliminate Safety Risks
Completely resolve inner wall collision issues and prevent breakage or leakage.
4. Achieve Lightweight Design
Reduce total weight to 420g while improving safety and increasing capacity.
4. Our Solution
Structural Redesign
We optimized the internal structure while keeping the original внешний appearance unchanged. This allowed us to increase capacity from 10oz to 12oz and eliminate inner wall collision risks.
Lightweight Engineering
By refining material composition and production processes, we successfully controlled the product weight to 420g.
Enhanced Safety Performance
We improved the cup’s impact resistance, ensuring it meets global safety standards and eliminates risks such as cracking, leakage, or injury.
5. Manufacturing Process
We implemented advanced ceramic production technologies:
- High-temperature firing to increase density and strength
- Precision double-wall assembly
- Optimized wall thickness distribution
- Secondary firing process for enhanced durability
All products were made with food-grade ceramic materials, ensuring compliance with global safety standards.
6. Execution Process
1. Requirement Alignment
Multiple technical discussions to confirm specifications and standards.
2. R&D and Prototyping
Dedicated engineering team conducted multiple rounds of testing and optimization.
3. Laboratory Testing
Samples were tested using impact standards (QB/T 1993-2012) to ensure structural safety.
4. Mass Production
Production processes were optimized for large-scale manufacturing.
5. Packaging
Handmade gift box packaging aligned with brand aesthetics and ensured product protection.
6. Final Inspection & Delivery
Full inspection and approval before shipment, with complete quality reports provided.
7. Quality Control
We established a strict multi-stage quality control system:
- Raw Materials: Food-grade ceramic with strict impurity control
- Production: QC checkpoints at every stage
- Finished Products:
- ≥98% pass rate in impact testing
- Tested for thermal shock resistance and sealing performance
- Packaging: 100% inspection of handmade boxes
8. Certifications
The products passed international certifications, including:
- FDA (USA)
- LFGB (Germany)
Ensuring full compliance for global market distribution.
9. Delivery Capability
Despite the absence of full automation, we:
- Built a dedicated production team
- Optimized scheduling and supply chain coordination
- Delivered 1.2 million units within 3 months
We continue to maintain stable production capacity to support large-volume orders.
10. Results
Product Performance
- 98% pass rate in impact testing
- Fully met all safety requirements
Order Growth
- Initial order: 200,000–300,000 units
- Rapid sell-out after launch
- Continuous repeat orders
Strategic Upgrade
- Became a Top 3 supplier among 20+ vendors
Market Impact
- Helped restore Starbucks’ double-wall cup market in North America
11. Client Feedback
“The professional R&D capability and reliable delivery capacity have solved our urgent needs. The high-quality double-layer cups have won wide recognition from consumers. We are very satisfied with the long-term cooperative relationship and look forward to deepening cooperation in more product categories.”
12. Long-Term Partnership
Since 2018, we have maintained a stable and long-term strategic partnership with Starbucks.
Our ongoing collaboration includes:
- New ceramic product development
- Support for sustainable supply chain initiatives
- Continuous innovation in coffee-related products
13. Conclusion
This case highlights our ability to deliver:
- Advanced ceramic R&D solutions
- Custom ODM development for global brands
- Large-scale production with reliable delivery
- Effective solutions to complex safety challenges
For brands in the coffee, hospitality, and retail sectors, we serve as a trusted long-term manufacturing partner, supporting product innovation and sustainable growth.
