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In the context of modern consumption, the combination of convenience and environmental responsibility is becoming increasingly important. Compostable cold plastic cups made from PLA have emerged as an optimal solution, maintaining durability and aesthetic appeal for beverages while minimizing negative impacts on the planet. With the ability to naturally decompose under suitable conditions and being completely free of synthetic plastics, this product not only meets the needs of the F&B sector but also helps businesses build a sustainable “green” image in the eyes of their customers.

They come in a variety of sizes (usually from 350ml to 1000ml) to suit different beverage capacities, and are commonly used in the food and beverage service industry.

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1. Industry trends

• The demand for environmentally friendly materials is on the rise: The packaging trends for 2024–2026 prioritize compostable or bio-based materials, minimalist design, transparency in sourcing, and end-of-life disposal information. Numerous reports and industry insights forecast steady growth for PLA cups (and compostable cups in general) due to consumer pressure and environmental regulations.
• Practical barrier: Although “compostable” products are widely promoted, the treatment infrastructure (industrial composting facilities) remains limited in many countries. For example, reports indicate a gap between the compostable claim and actual disposal capability — in the U.S., only a small percentage of the population has access to industrial composting. This affects the real environmental impact of PLA cups if they are not collected and processed along the proper channels.

Challenges and new trends:

• Sustainability pressure: The plastics industry is facing great pressure on environmental issues, with the trend of increasing the use of recycled plastics and bioplastics.
• Advanced technology application: Automation and artificial intelligence will be applied to improve production efficiency and product quality, helping to minimize environmental impact.
• Responding to market demands: Businesses need to quickly grasp new trends, invest in technology and sustainable materials to develop and maintain competitiveness.

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2. Product specifications and character

• Main material: Polylactic Acid (PLA) derived from plant starch (corn, sugarcane).
  • Advantages: renewable source, BPA-free.
  • Drawbacks: lower heat resistance compared to technical plastics.
• Standard sizes/volumes: 7 oz / 9 oz / 12 oz / 16 oz — commonly used in the F&B industry.
• Wall thickness (typical factory example): thin PLA cups may be ~0.5–0.6 mm; commercially, 0.53 mm PLA cups are produced via molding/injection techniques. Thickness directly affects stiffness and the speed of composting.
• Mechanical properties (general reference): Tg ≈ 55–60°C; melting point 130–180°C (depending on purity/crystallinity). PLA is more brittle than PET/PP and less impact-resistant, but sufficient for cold beverages. Due to the low Tg, it is not suitable for hot liquids and has lower heat resistance than technical plastics.
• Compostability: PLA effectively decomposes only under industrial composting conditions (high temperature, adequate humidity, time, and stable microbial activity); it does not rapidly degrade in home composting, oceans, or landfills.

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3. Raw materials

• Main Material: PLA (Polylactic Acid) PLA is a biopolymer derived from renewable resources such as corn starch, cassava, sugarcane, or sugar beet. The production process generally involves three main steps:

  1. Sugar extraction (glucose, sucrose) from plant starch.
  2. Fermentation of sugar → lactic acid using microorganisms.
  3. Polymerization of lactic acid into Polylactic Acid (PLA) — a biodegradable bioplastic.

• Additives (if any) Some manufacturers may include additives to enhance flexibility, strength, or processability, such as:

  • Biobased plasticizers: reduce brittleness of PLA.
  • Inorganic fillers (e.g., talc, calcium carbonate – CaCO₃): increase stiffness and reduce cost.
  • Nucleating agents: help control crystallinity, improving rigidity and clarity.

  Note: If additives are used, the compostable certification must be verified, as they may affect biodegradability.

• Other components (if coated or with lids)

  • Cup lids or coatings are typically made from PLA to maintain compostability.
  • Some premium products may have a thin PLA coating to enhance water resistance or provide a glossy finish.

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4. Sizes

Cold plastic cups come in a variety of sizes, with common sizes being Size S (350-400ml), Size M (400-500ml), and Size L (500-700ml), depending on the type of beverage and manufacturer. Specific sizes may include 360ml, 450ml, 500ml, 600ml, 700ml, or other capacities depending on the type of cup.

Popular sizes by capacity:

• Size S (Small): Usually has a capacity of 350ml to 400ml, suitable for coffee, iced tea, or filtered water.
• Size M (Medium): Common with a capacity of about 400ml to 500ml, suitable for milk tea, juice, or iced coffee.
• Size L (Large): Capacity from 500ml to 700ml, ideal for larger drinks such as milk tea, smoothies, or juices.

Specific size examples:

• 360ml: A popular 12oz cup, used for many types of cold drinks.
• 500ml: Another popular capacity size, often used for larger drinks.

Note:

• Plastic cup sizes are usually determined by capacity (ml or oz) rather than just physical dimensions (height, diameter).
• Choosing the right cup size often depends on the type of drinks you serve and the needs of your customers.

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5. Processing

1. Raw Material Preparation

   • Main material: PLA (Polylactic Acid) pellets, derived from renewable sources such as corn starch, sugarcane, cassava, or sugar beet.
   • Additives (if any): plasticizers, fillers, or nucleating agents to enhance flexibility, stiffness, or processability.
   • Note: materials must have compostable certification if the final product is intended for industrial biodegradation.

2. Compounding & Melting

   • PLA pellets are thoroughly mixed with additives, if used.
   • Heated in an extruder or injection machine to the appropriate temperature (~170–190°C) until PLA melts and becomes homogeneous.
   • This ensures the material has the right viscosity for cup forming.

3. Molding/Forming

   • Injection Molding: molten PLA is injected into cup molds and cooled rapidly to maintain shape.
   • Thermoforming: PLA sheets are softened with heat, then vacuum-formed or pressed into cup molds.
   • Note: temperature and pressure must be carefully controlled to prevent brittleness, cracking, or deformation.

4. Cooling & Shape Stabilization

   • Formed PLA cups are rapidly cooled to preserve rigidity, transparency, and shape stability.
   • Cooling time and airflow affect cup warping and wall quality.

5. Finishing (if applicable)

   • Trimming: smooth edges for safe use.
   • PLA coating or logo printing: for water resistance or branding purposes.
   • Lid assembly: if the cup includes a PLA lid.

6. Quality Control (QC)

   • Check dimensions, volume, and wall thickness.
   • Inspect transparency, surface, and integrity (no cracks).
   • Test heat resistance and suitability for cold beverages.
   • Verify compostability if the product is marketed as biodegradable.

7. Packaging & Storage

   • PLA cups are stacked neatly in cartons or protective bags to prevent damage.
   • Store in a dry place, away from high temperatures and direct sunlight to avoid premature deformation.

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6. Manufacturing/printing methods

Cold cups made from PLA (Polylactic Acid) have a low thermal tolerance (Tg ~55–60°C) - (Tg :glass transition temperature = starts to soften) so printing methods must be chosen carefully to avoid deformation or surface damage. Here are the common printing methods:

Screen Printing / Silk Screen

• Principle: Ink is pressed through a mesh onto the cup surface.
• Advantages:
  • Suitable for cups with slightly curved surfaces.
  • Relatively low cost for medium to large quantities.
  • Thick, durable ink with vibrant colors.
• Disadvantages:
  • Typically limited to 1–2 basic colors; complex multi-color designs are challenging.
  • Slower than roll-to-roll methods.
• Note: Use food-safe ink suitable for contact with food.

Flexographic Printing (Flexo)

• Principle: Printing is done on PLA-coated sleeves or films, which are then wrapped or adhered to the cup.
• Advantages:
  • Efficient for large volumes, low cost per unit.
  • Can print on PLA-coated paper sleeves or adhesive films.
• Disadvantages:
  • Cannot print directly on curved cups; requires sleeves or films.
  • Image details are less sharp than offset printing.

Decal / Label Printing

• Principle: Print on PLA-coated labels, paper, or PET film, then apply to the cup.
• Advantages:
  • Flexible and easy to change designs.
  • Ideal for seasonal promotions or campaigns.
• Disadvantages:
  • Increases cost; improper application may cause peeling.
  • Labels must be food-contact safe.

Digital / UV Printing

• Principle: Use digital or UV printers to print directly on the cup or PLA-coated sleeve.
• Advantages:
  • Flexible for small orders or personalized printing.
  • High detail and vibrant colors without the need for printing plates.
• Disadvantages:
  • Higher cost per unit compared to screen or flexo printing.
  • UV printing temperature must be controlled to prevent PLA deformation.

Important Notes for PLA Printing:

• Use food-safe inks and adhesives, free of BPA, safe for food contact.
• Avoid excessive heat during printing to prevent brittleness or warping.
• For compostable cups, ensure inks and materials do not affect biodegradability.

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7. Production lead time (general estimate)

• Samples: 3–10 days (depending on whether or not a logo is printed).
• Stock orders: ready-to-ship within a few days – 2 weeks.
• Custom printed orders: 2–6 weeks is typical.

Factors affecting production time

• Quantity of products: The larger the order, the longer the production time.
• Production process: Manufacturing methods such as injection molding, blow molding have different times, affecting the time to complete the product.
• Technology and machinery: Modern machinery can speed up production.
• Product design: Complex designs may require longer production times.

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8. Price and MOQ (Minimum Order Quantity)

Product Pricing

The price of PLA cold cups depends on various factors such as cup size, thickness, printing options, and whether lids are included.

• Unprinted cups (standard clear cups): considered the base price (100%), suitable for large-scale or bulk orders.
• Custom printed cups (with logo/branding): generally 15–30% higher than unprinted cups, depending on:
  • Number of printing colors and printing method (screen printing, UV printing, or sleeve).
  • Printing area (full wrap or partial print).
  • Order volume (smaller runs have a higher cost per unit).
• Cups with PLA lids included: typically 10–15% higher than plain cups without lids.
• Double-wall cups or coated types: may cost 20–40% higher than standard PLA cups.

👉 For large F&B chains, suppliers often provide all-inclusive quotations (cup + print + lid) to optimize cost and ensure brand consistency.

Minimum Order Quantity (MOQ)

• Standard unprinted cups: common MOQ ranges from 10,000 – 20,000 pcs.
• Custom printed or branded cups: MOQ is usually 30,000 – 50,000 pcs, as printing molds or sleeves must be set up individually.
• Trial or sample orders: some manufacturers may support smaller MOQs (around 1,000–2,000 pcs) if using digital or on-demand printing (POD) technology.

Factors Affecting Price & MOQ

• Cup size: 7 oz < 9 oz < 12 oz < 16 oz (larger cups have higher unit prices).
• Cup thickness: thinner cups decompose faster but are less rigid.
• Material type: 100% virgin PLA is more expensive than PLA blended with fillers.
• Certification requirements: standards such as EN 13432 or ASTM D6400 may increase costs due to testing and certification fees.
• Logistics and import taxes: also affect the final landed cost.

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9. How to choose suitable options

Determine the intended use and type of beverage

• Common cold beverages (juice, milk tea, iced coffee, soda, smoothies): → Choose a standard clear PLA cup with medium wall thickness and a capacity of 12–16 oz. → Can be paired with a flat lid or domed lid depending on the beverage type.
• Beverages that need to stay cold longer or have heavy toppings: → Prefer thicker PLA cups or double-wall cups to increase rigidity and reduce condensation on the outside.

⚠️ Important note: PLA cups are not suitable for hot beverages (above 45–50°C) because PLA has a low glass transition temperature (Tg) and can deform, soften, or leak when exposed to high heat. → Therefore, PLA is only recommended for cold, chilled, or iced drinks.

Balance brand image and cost

• If a business wants to enhance brand recognition, choose cups with printed logos or branded sleeves. This is suitable for store chains, premium brands, or promotional products. Although printing adds 15–30% cost, the direct marketing impact is often high.
• If prioritizing cost efficiency and mass adoption, choose plain cups or single-color prints, which are easier to produce at scale.

Consider order volume and storage capacity

• Small businesses or new cafes: opt for standard PLA cups without printing; low MOQ, easy to restock.
• Large businesses, store chains, or distributors: place custom printed orders with higher MOQ to reduce unit costs and ensure consistent brand presentation.

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10. How to preserve cold plastic cups with PLA

How to Use PLA Cold Cups

• For Cold Beverages Only: PLA cups are suitable only for cold drinks: water, fruit juice, iced milk tea, iced coffee, soda, smoothies. Do not use for hot drinks (>50–60°C), as PLA has a low glass transition temperature (Tg ~55–60°C). Exposure to high heat can cause the cup to deform, soften, or leak.
• Use Compatible Lids: When serving cold beverages, use PLA lids or compostable lids with a straw slot or flat top. Choose lids that match the cup size and drink type to prevent spills and leaks.
• Avoid Strong Impacts: PLA is more brittle than technical plastics like PP or PET, so avoid dropping or applying strong force. For drinks with heavy toppings (e.g., boba, large ice cubes), prefer thicker PLA cups or double-wall cups for added strength.

How to Store PLA Cups Before Use

• Avoid High Temperatures: Do not place cups near stoves, microwaves, or hot water sources. High heat can warp or deform the cup and reduce its lifespan.
• Avoid Direct Sunlight: Store in a dry, well-ventilated place, away from prolonged direct sunlight to slow down premature degradation.
• Avoid Excess Moisture: Do not soak cups in water for extended periods. Keep in a ventilated environment and avoid high humidity to maintain surface quality and rigidity.
• Avoid Strong Chemicals: Do not expose cups to solvents, acids, or harsh detergents. These chemicals can cause discoloration, cracks, or reduce biodegradability.
• Keep in Original Packaging: If stored in a warehouse, keep cups in sealed packaging to protect from dust, insects, and oxidation. This helps PLA cups maintain clarity, stiffness, and food safety before use.

Notes on Compostability

• PLA is compostable effectively in industrial composting conditions (~60°C, high humidity, active microorganisms).
• In home, soil, or natural environments, composting may take 1–5 years.
• Proper storage ensures product longevity and helps maintain compostability when disposed of correctly.

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11. Summary

PLA cold cups open new opportunities for brands seeking to stand out in the beverage market: they represent a strategic choice that is both market-oriented and capable of enhancing brand value. The decision to introduce PLA into the supply chain is the first step on a journey — it should be viewed as an investment that can deliver a competitive advantage if implemented correctly. With a pragmatic mindset, treat PLA as a tool for innovation rather than a perfect solution, and use it to experiment, learn, and refine your product strategy based on market feedback.

Designing and printing on cups not only helps businesses boost brand recognition and communicate a green message, but also creates a distinctive visual impact and customer experience. Therefore, when using and printing on cold plastic cups, businesses should focus on selecting suitable materials, modern printing techniques, and creative designs—ensuring food safety while enhancing brand value in today’s competitive market.