Flight Coffee Hangar is one of Wellington's most distinctive specialty cafés, a brand with genuine craft values, a strong visual identity and a reputation for quality that runs from bean to cup. When they came to us needing custom drink coasters, the ask was straightforward, but getting it right took a bit more than hitting print.

Their initial spec called for a standard card stock, which we advised against, as coasters need to absorb moisture, and a typical 350gsm stock simply isn't built for that. We recommended 275gsm Coaster Board instead: a purpose-made stock that handles condensation, holds up through a busy café shift and still takes print beautifully. We also suggested a minor size adjustment, from 90mm to 93mm, to optimise material usage without any visible difference to the finished piece.

Print was handled on our Konica Minolta AccurioPress C4070, with in-line quality control ensuring consistent colour across the full run. Both sides were printed in CMYK to match Flight Coffee's branding, then die-cut to a precise 93mm circle using our JWEI 6040, no tooling required, clean edges every time.

The initial run of 500 was followed three months later by a reprint of 1000, made straightforward because we retained the artwork and had the production process dialled in. A small detail we were glad we caught: a spelling error in the supplied file, corrected before anything went to press.

The result is a coaster that looks the part, performs under real café conditions, and carries the Flight Coffee brand with the quality it deserves.

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