Behind the Scenes: The Technology and Passion in Manufacturing the Unbreakable "Transparent Teapot"

Hello, this is Tanimoto from Senchado Tokyo.

One of our most popular products at Senchado Tokyo is the unbreakable transparent teapot "Toumei Kyusu". We're grateful for the many customers who use it and share their experiences on social media.

To reach the point of selling hundreds of thousands of these teapots, we've received tremendous support from our manufacturing partners, especially those involved in the resin production. We've faced challenges, caused some inconveniences, and continuously improved step by step.

The Philosophy Behind Our Product

In today's world, consumers are increasingly interested in the "ideology" and "philosophy" behind the products they use. We believe it's important to share our manufacturing process and the thoughts behind it, hoping this transparency will give our customers confidence in their purchase.

Respecting the Makers

In the past, we've experienced periods where demand outpaced our production capacity, leading to month-long wait times for customers. During these times, we asked our resin manufacturing partners to maintain high quality while increasing production speed - a challenging balance that caused strain.

We could have prioritized customer demand at all costs, but we chose a different path. We believe that our manufacturing partners and staff should be respected just as much as our customers. Our goal is to find a way where everyone involved - customers, makers, and staff - can be happy.

Sustainable Growth for Long-term Value

Our approach isn't about avoiding improvements or evolution, but about healthy growth that allows us to provide consistent value to our customers. We may not offer the endless convenience of a convenience store, but we aim to deliver solid value within our responsibilities. We hope to build good relationships with customers who appreciate this philosophy.

The Manufacturing Process

Recently, we visited the factory in Ishikawa Prefecture to review and adjust our manufacturing methods. As part of the manufacturing community, we strive to reduce production waste and create long-lasting products, aiming for a sustainable business with minimal environmental impact.

Contrary to what some might expect, the transparent teapot involves many manual processes. While we've gradually introduced automation and mechanization, the product's unique nature required us to start with mostly handcrafted methods.

The Art of Resin Molding

The heart of the process is the resin molding. Robot arms now handle some tasks that were initially done by hand, such as removing the hot resin from the mold and cooling it. However, human expertise is still crucial in operating these machines, adjusting for factors like temperature and humidity to ensure high-quality results.

These operations, now performed by robots, were initially done by hand when production began. The "transparent teapot" is an "ultra-thick" molded product that defies conventional resin manufacturing norms. The molding technique and required product quality were so far beyond industry standards that it caused significant challenges (for which the narrator apologizes). The narrator expresses deep respect and gratitude for overcoming these hurdles to manufacture the product.

Even with today's mechanization, operating these robots remains a human task, requiring adjustments based on factors like temperature and humidity in the production area. The molding process must account for moisture content in the resin raw materials to prevent defects and ensure a clean finish. According to the production manager, Mr. Kitamura, it's "almost like working with a living thing."

 

Turning Gate Processing into a Design Feature

After cooling, our transparent teapot enters the post-processing stage. Unlike most resin products, this teapot demands an exceptionally high level of aesthetic appeal. What most people don't notice is that we've meticulously designed the teapot to make the "seams" - such as parting lines and gates - nearly invisible.

When customers tell us they "thought it was glass," it's because of this high-difficulty design that pays careful attention to how light enters and reflects off the teapot, creating a beautiful visual effect.

The "gate" - the point where resin is injected into the mold, which typically leaves a visible mark - is carefully treated. We use a drill press to smooth it down, then apply a laser engraving by hand. This process results in a bottom surface that's seamlessly beautiful, with no noticeable imperfections.

This attention to detail in our manufacturing process is what sets our transparent teapot apart, allowing it to rival the beauty of glass while maintaining the durability of resin. It's a perfect blend of traditional craftsmanship and modern technology, resulting in a product that's as visually stunning as it is functional.

Meticulous Craftsmanship: From Our Hands to Yours

Before our transparent teapots reach your hands, they undergo several careful, hands-on processes. The journey doesn't end with resin molding; in fact, that's where the artisan's touch becomes crucial. While we've gradually introduced automation and mechanization over the past three years - a period marked by significant challenges and learning - certain aspects still require the irreplaceable human touch.

Visual inspection, in particular, remains a task that machines can't quite master. Our skilled craftspeople conduct multiple quality checks at various stages, including at the factory and during packaging. This ensures that each teapot meets our exacting standards before it's shipped to you.

Every day, our team meticulously examines hundreds, sometimes over a thousand, individual teapots. They're checking for any irregularities in shape or potential defects - a task made particularly challenging by the teapot's transparency. It's a testament to their skill and dedication that they can spot even the slightest imperfection in these crystal-clear products.

Seeing rows upon rows of these teapots lined up for inspection is truly a sight to behold. The way they catch and reflect light creates a dazzling, almost magical display. It's a vivid reminder of the care and attention that goes into each piece we produce.

This level of craftsmanship and quality control is what sets our teapots apart. When you receive one of our products, you can be confident that it has passed through many pairs of skilled hands, each dedicated to ensuring you receive a teapot of the highest quality.

A Team Effort

Consistent, stable manufacturing is a team effort. It's not just about one craftsman's skill, but about the entire team improving their technical abilities and passing the baton from upstream to downstream until the product reaches the customer. We hope our customers feel part of this manufacturing circle, helping to pass it on to the next generation.

Our Commitment to Sustainability

We're committed to updating tea culture for future generations, and this includes making the production of our transparent teapot more sustainable. We're focusing on two main actions:

1. Minimizing manufacturing waste
2. Utilizing products that don't meet our strict quality standards

For the second point, we're considering donating to educational institutions or offering "outlet" sales to repeat customers who understand our process. We hope this "warm distribution" will allow these unique pieces to find appreciative homes.

Aiming for "Warm Distribution

We hope this behind-the-scenes look gives you a deeper appreciation for our transparent teapot. We're continuously improving both our teapots and our teas, and we're grateful for your continued support. Thank you!