project-image

COFFEEJACK™- The Pocket Sized Barista

Created by HRIBARCAIN

Pollution Saving Espresso Maker No Bigger than a Cup

Latest Updates from Our Project:

Manufacture Update + Timeline Analysis
over 2 years ago – Fri, Aug 13, 2021 at 02:13:16 AM

Hi Backers,


We hope you are all well.


We've received a few requests asking for further explanation regarding the projects timeline, reasons for delay and its current status. The information below, summarises where we started and where we are today.


We appreciate this is a lengthy update but it is important to understand the process we are going through and why it has benefited the project in so many ways. Please take the time to read through.


This is not an update filled with waffle or excuses, it’s purely highlighting milestones and clear direction which is essential for the project's success.


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Jan 2020

FUNDS RECEIVED FROM KICKSTARTER

Discussions continued with our manufacturers following the campaign. As funds had just been received, serious discussions regarding production methods, MOQ’s, logistics could now take place.


Feb 2020

DESIGN IMPROVEMENTS

Update #8 stated that we had made some design improvements, these changes were inspired by our backers feedback. Throughout the two month campaign, we listened to your feedback, suggestions and potential improvements. Not only did we listen to your suggestions, we acted on them.

UPDATE #9 - COVID 19. The virus was causing problems in China for the development of our design changes. We stated that development would continue back in the UK. We purchased our own 3D printer to speed up the process.


March 2020

COVID-19 LOCKDOWN

Update #11 - Images showing samples of the design changes. However, COVID-19 is still causing production issues. We stated that development has moved to the UK in an attempt to save time. We packed up the office and worked from home following government instruction for UK lockdown.


April 2020

COVID-19 LOCKDOWN

Update #13 - COVID-19 is still causing issues for production. We can only apologise for the inconvenience but is was out of our hands. Development samples were dependent on the companies in operation. The whole of the UK was in lockdown.


June 2020

FACTORIES BACK IN PRODUCTION

Update #18 -We announce factories are back in production and that we are yet to confirm our injection moulding partners. This accounts for a large portion of the project and the main reason for unforeseen future delays.


JULY 2020

NEW DELIVERY DATE DUE TO PANDEMIC/DESIGN CHANGES

We proposed a delivery date between Sept-Oct 2020 provided we do not encounter any mould amendments. We stated that amendments are a possibility.


Update #19: DELIVERY DATE PROPOSAL: September/October 2020. This is a milestone update as it states our estimated delivery date as a result of delays created by the pandemic/improvements. It also says this date is realistic providing there are no mould amendments required.


August 2020 

MOULD PRODUCTION (not product production)

We started production (not physical manufacture but mould design production). This threw up lots of hurdles that we needed to overcome for the injection moulds. We apologise for the way in which this was communicated as there is a big difference between the mould production and product production. As we hope you can understand, we were extremely excited and couldn't wait to tell you all but the terminology could have been better!


September 2020

MOULD SPECIFICATION 

We stated that we are still working on mould specs with our manufacturers. Each component of Coffeejack required an extensive amount of documentation and approval before cutting any moulds. Update #20: We show a video of the production document and the amount of work that it had required before mould approval.


October 2020

TIMELINE RELEASE

We released a timeline from our manufacturer and apologised for the delay. Please see the design improvements to Coffeejack below, all developed between Jan-Oct:

  • Full width water spreader for better extraction
  • Larger water chamber
  • More compact design
  • Shallower basket to increase espresso yield capability
  • Safety water trap
  • Sealed chamber for improved hygiene
  • Improved Sealing and reliability
  • New valves to improve maintenance
  • Pressure Regulation
  • Increased basket capacity
  • Custom grip
  • Narrower basket to fit a wider variety of mugs
  • Anti-Drip valves
  • Custom filters
  • New Locking Mechanism
  • Soft place rubber
  • Thicker wall structures
  • New Packaging (see below)
  • Instruction manual (see below)

We decided to not pursue OPV development as testing proved ineffective.


November 2020

ISSUE WITH MOULD

We encounter an issue regarding a release mould for the injection moulding tool. We had no choice but to re-design this component and it was going to cause a delay.


December 2020

RE-DESIGNING PART FOR NEW MOULD

In order to test the design changes we had to send for multiple 3D prints, then send to a machinist in the UK for finishing. Each iteration had a significant affect on timeline (3D print 3-4 days, CNC machining 1-2 weeks.) If the change did not work, we had to start again. Update #27 - We showed images of tampers in production.


JAN 2021

COVID-19 LOCKDOWN

UK is now in full lockdown following government instruction as per March 2020. We stated that we are on track for May 2021 delivery providing there are no development amendments. Update #31: We stated:

“We will test seal efficiency to demonstrate when there is a slight variance in the dimension of plastic parts. This often occurs due to variable cooling rates post mould. Our design ensures the parts cool evenly so material shrinkage is kept to an absolute minimum. However, we must account for variance and its affect on a large production run, primarily with regards to high pressure sealing when exposed to heat.”

IMPORTANT: This testing phase was known and highlighted by ourselves in Jan 2020. When dealing with high pressure, heat and fluids, we knew this was a critical measure to analyse. Consequently, this is one of the reasons for delay. We see this as a positive, as we are essentially tick boxing our planned testing measures and catching any manufacture defaults before reaching mass production. This will ensure you receive a high quality, reliable product as a result.

The image below shows the iterations we went through to make the design changes and get to a mould approval stage. This box, with 3D and CNC machining equates between $10,000-15,000 in prototyping.

FEB 2021

CHINESE NEW YEAR

Chinese New Year. Manufacturers are shut down until the end of February. Update #33: Final moulds have started to be machined.


MARCH 2021

MOULD DESIGN COMPLETE

We show images of the injection moulds. We have provided 50% upfront payment for these moulds (design, steel and machining)


APRIL 2021

MOULD MACHINING COMPLETE & FIRST INJECTION MOULDED PARTS

We show images of the cut moulds. Update #36: We show images of the first injection moulded parts (such a massive milestone after years of development!)


MAY 2021

DRAFT ANGLE ISSUE

We state we are happy with the quality of the parts but that there a few hurdles to overcome for the next batch. Main issue: Draft angle on piston prevented testing of the parts. CNC amendments take 3-4 weeks.


JUNE 2021

PACKAGING DESIGN COMPLETE & FIRST INJECTION MOULDED COFFEEJACK

We announce production and show video/images of the packaging with an assembled Coffeejack.


JULY 2021

CYLINDER CHANGE REQUIRED

The mass order is produced in stages to eliminate risk eg. 1 off sample (test), 10 samples (test), 50 samples (test) etc. Following testing of multiple Coffeejack’s we encountered an issue with the cylinder. UPDATE #41: Cylinder diameter issue is better but still remains. Every time we test our samples, we provide feedback to our manufacturers, they then offer solutions with timeframes and we update our backers. Unfortunately this does take time to not only find any issues through extensive testing, but the moulds have to be re-welded and machined. This takes between 1-3 weeks depending on the modification. Seeing as the moulds had to be re-worked, we made a design improvement for the valve upgrade (there was a $3000 on-cost plus additional production cost for the new valve). Quality is priority, not cost. The screenshot below shows just one of our testing methods for analysing the cylinder dimensions and how we relay our findings to the manufacturers:

Data recording at various points within internal high pressure cylinder
Internal Bore Gauge

AUGUST 2021

We collected the latest samples. After attempting to fit the new valves it became clear that the valve hole diameter was undersized (3.2mm Dia, not 3.8mm Dia). This is due to the calling rate from the mould for such small geometry.


TODAY AND ONWARDS…..

More cooling channels are being machined in order to control the shrinkage rate around the the valve hole. We are asking our manufacturers to pull out every stop to make sure the changes are made immediately. It has been arranged for their engineers to come in over this weekend work on the modifications. Timeline has been estimated as 10 days, plus the inevitable shipment from China (3-4 days).


We really hope the above provides some additional insight as to how one small necessary change can take weeks to amend, test, approve/reject. We completely understand how frustrating the delay must be for you all and we can only say…..we get it! We want to complete this promise to you all, celebrate its success then grow the brand and create more exciting products. But that will only happen if we continue to be relentless, critical, hard-working and logical in our approach to mass manufacture otherwise, we would be bound for mass complaints! We want everyone to be overjoyed with the result, and that you will be.


These amendments will take around two weeks to arrive in the UK. In the meantime we will finalise the instruction manual/user maintenance artwork and copy. This has the shortest lead time so it will not affect production schedule.


Delivery estimate (October 2021):


Reason:

End of August: Receive new samples with 3.2mm Dia valve hole. Test all geometry/functionality over 10-20 components.


Beginning of September: APPROVAL - Providing there are no amendments to be made. As we have mentioned throughout the campaign, this is always a possibility but something we continuously endeavour to avoid.


September: 3-4 week production and assembly.


Beginning of October: Shipment to Logistics


October: International Shipment


Please note: There is every possibility that these dates could move forward or backward. We will keep you notified every step of the way as and when we receive information.


Thank you for your continued support, it really does mean everything 🙏


Ashley and Matthew

Manufacture Update
over 2 years ago – Sat, Aug 07, 2021 at 01:40:07 AM

Hi Backers,


Current Manufacture Status:

  • Cases: 80% Complete
  • Tampers: Complete
  • Tamper Cases: Complete
  • Elevation Stand: Complete
  • Extras (grinders, scoops, cups, etc): 80%% complete
  • Injection Moulded Components (see below)
  • Metal Components (see below)

Based on results from our 10th July update (samples received 4th Aug):


10th July: "1- There is a slight variance across the diameter of the high pressure cylinder from top to bottom"

Sample Feedback: This issue has been resolved with the new samples, we are happy with the results.

APPROVED ✅

10th July: "Valve hole geometry and Valve Spec" 

Sample Feedback: Our spec states 3.8mm diameter hole for the valve. However, the samples are currently reading 3.2mm Diameter. This means that the valves are difficult to fit and the activation force is not representative to spec. This issue has been raised with the manufacturers and is currently being reviewed with the factory engineers. 


Our manufacturers are usually quick to propose a solution, as soon as we hear from them we will send a further update. With regards to timeframe, we will be able to update as soon as we recieve the feedback and solution timeline. This should take no more than 2-3 days for a full response so we will be in touch very soon.


As always, we are pushing to expedite the process in all ways possible.


Thank you and have a fantastic weekend,


Ashley and Matthew

Manufacture Update
over 2 years ago – Thu, Aug 05, 2021 at 04:26:15 AM

Hi Backers,


We wanted to let you know that the samples arrived in the UK late yesterday evening, we drove to the main depot for collection to speed up the delivery process.


Currently we are in full test mode! We'll continue testing, measuring all components and provide our results as soon as possible. We just wanted to let you know that a manufacture update will be on its way and we are keeping busy!


We will be working over the weekend with these parts and hopefully have an update before Monday. 


Thank you


Ashley and Matthew

Manufacture Update
over 2 years ago – Sat, Jul 10, 2021 at 05:45:51 AM

Hi Backers,


We hope you are all well.


We’ve been talking with our manufacturers throughout the day, everyday. Below shows a summary of the discussions.


Current Manufacture Status:

  • Cases: 50% Complete
  • Tampers: Complete
  • Tamper Cases: Complete
  • Elevation Stand: 85% Complete
  • Extras (grinders, scoops, cups, etc): 50% complete
  • Injection Moulded Components (see below)
  • Metal Components (see below)

Whilst we have lots of manufacture either complete or almost complete, we do have a couple of areas to address regarding the injection moulded components. These have been brought to our attention following our quality checks over a larger production run.


Please note: These are not ammendments that create significant delays. The changes should take no more than two weeks (plus shipping for UK approval).


1- There is a slight variance across the diameter of the high pressure cylinder from top to bottom. It has not prevented Coffeejack from functioning, however we are not willing to accept ANY variance across parts on such a large production run for quality reasons. This must be fixed and we have a solution in place. This is due to variable cooling rates, even though there are multiple cooling channels. We have a solution in place to fully rectify this issue but it requires the tool to be adjusted. As mentioned it is very minor, but we need to eliminate any risks as we gear up the production.

2- Valve hole geometry and Valve Spec. We have been testing Coffeejack to pressures in excess of 20 bar in order to simulate cases of misuse. We believe we can optimise the priming speed of the piston by changing the hole geometry. In doing this, we are also able to upgrade two of the valves to increase it lifespan before replacements are required. We want Coffeejack built like a tank!

This is an upgrade we are making whilst the main body is being machined, therefore it doesn’t consume any more production time.


Regardless of the main body changes above, we are able to continue manufacture for other plastic components.


In order to make these very minor changes, it costs approx. $3000. Every time we make a tool amendment, similar costs apply. There is a reason for saying this….

There is NO expense spared to ensure Coffeejack meets the high standards promised by myself and Matthew. It MUST be right.


Please see the latest videos of Coffeejack below. Everyday we have started work drinking a fantastic espresso (espressos!). Its been a very enjoyable testing experience! We've uploaded three different extractions, all using around 15-16g of grind:



We should have a batch run returned to us in approximately two weeks time. We are seriously close but as mentioned above, we’ve worked too hard to fall at the last hurdle. Also, your patience must be sufficiently rewarded and we do not take this responsibility lightly.


Have a great weekend


Ashley and Matthew

Let's go, we're in production!!!! 🍾
almost 3 years ago – Wed, Jun 23, 2021 at 01:37:36 AM

Hi Backers,


Coffeejack is now in final production!! 🍾


The most recent injection moulded samples arrived three days ago, which have since undergone extensive testing and passed with flying colours.


We fully appreciate this project has endured its delays and your patience has been sincerely appreciated. 


The final result is so worth it! 






Whilst Coffeejack has been with our manufacturers, we have been working hard on the finishing touches for the project such as packaging, user manual & maintenance, logistics (shipping).


We are exceptionally proud and feel confident you will all be delighted with your very own Coffeejack!

Over 4 years of blood sweat and tears makes this stage in the project a huge milestone, and you all helped to make it happen! Thank you 🙏


We were hoping for the parts to arrive towards the end of last month, however there was a factory delay and a subsequent port closure, preventing shipping. Sorry the update is a little later than usual, we were here in the UK waiting for the samples, hoping to give you some good news much sooner. 


We now are manufacturing 18,000+ units which should take anywhere between 3-4 weeks (providing there are no issues during assembly). As ever, we will keep working to expedite timelines in any way possible. Shipping will commence IMMEDIATELY after assembly and quality control is complete. 


Thank you for your continued patience and have a fantastic weekend. 


Ashley and Matthew