Why you may receive more (or less) than your order of custom coffee packaging
At EcoBarista, we pride ourselves on delivering high-quality, sustainable custom coffee packaging solutions, and transparency is at the core of everything we do. One question we’re often asked is: “Why do I sometimes receive more (or fewer) units than I ordered?” This is due to standard industry practices that allow for print quantity variances, which are clearly outlined in our terms as a potential fluctuation of ± 15%.
Let’s explore why these variances occur and how they’re a natural part of large-scale printing, particularly in the production of flexible, eco-friendly packaging.
1. The Nature of Large-Scale Production
When manufacturing custom-printed flexible packaging in large volumes, efficiency is super important. However, slight over- or under-runs can occur due to the high-speed nature of the printing process.
In many cases, producing more than the ordered amount accounts for potential spoilage, ensuring enough units meet the required standards after quality checks. While we aim to match the exact order quantity, minor variances in machine calibration or substrate tension can result in overproduction or, in rare cases, underproduction.
2. Why We Aim for Over-Production
From a customer service perspective, delivering fewer units than ordered never results in a happy customer, and that’s something we want to avoid at all costs. That’s why we always aim for an overrun rather than an underrun. By producing slightly more units, we ensure you receive the full value of your order, with the added bonus of any extra units at the same per-unit cost. This approach helps us maintain customer satisfaction and ensures you have the stock you need, without unexpected shortages.
3. Balancing Efficiency and Waste Reduction
The ±15% variance also helps us minimise waste and operate efficiently. Producing the exact number of units would require frequent machine stops for recalibration, leading to inefficiencies, wasted resources, and higher costs. Allowing for small print variances lets us run machines smoothly, helping to reduce environmental impact, align with our sustainability goals, and keep prices competitive.
This flexibility is part of our commitment to both sustainability and providing cost-effective packaging solutions for our customers.
4. Material and Setup Considerations
The flexible packaging materials we use—whether compostable or recyclable—have unique properties that can impact production. During the printing process, substrates may stretch or contract slightly, affecting the total number of units produced. Each print run also requires “make-ready” material for machine setup, which can sometimes lead to minor overproduction, particularly on larger orders.
5. Quality Control and Spoilage
Maintaining the highest quality standards is a priority for us. However, during any print run, some units may not pass quality checks due to minor defects or misprints. To ensure that you still receive the full order quantity, we often produce extra units. If more than anticipated pass quality control, you may receive more units than ordered—a result of our effort to meet your needs while ensuring product quality.
6. Cost Efficiency for You
Producing slightly more units during a single run is often more cost-effective than re-running a production line for a shortage. By aiming for over-production, we avoid the risk of running short on your order, which keeps your costs stable and prevents delays in delivery. Any overrun units are billed at the same unit price, so you benefit from a bit extra without paying more.
7. Why the ±15%?
The ±15% variance is an industry standard that provides flexibility in managing both over- and underproduction. It allows us to optimise production efficiency and maintain quality, all while ensuring you receive your order on time. For example, if you order 10,000 units, you may receive anywhere between 8,500 and 11,500. While this range may seem broad, it reflects the practical realities of large-scale printing and helps keep operations smooth and sustainable.
8. Sustainability and the Bigger Picture
Sustainability is at the heart of everything we do. Allowing for print variances helps us operate more efficiently, reducing waste and conserving resources. By embracing this approach, we ensure that our packaging products are not only high-quality but also doing the right thing by the planet.
TLDR: A Win-Win for Quality and Sustainability
Print quantity variances are a natural part of flexible custom coffee packaging production, and they contribute to improved efficiency, reduced waste, and consistent quality. At EcoBarista, we believe in keeping our customers happy by aiming for over-production to avoid shortages and ensure you receive the stock you need. This approach supports both customer satisfaction and our broader mission to create sustainable packaging solutions that protect the planet.
If you have any questions about print quantities or our production process, we’re always here to help. Reach out to our team, and we’ll be happy to chat more!
