The Day I Had to Scrap 20,000 Products

Running a small business comes with its share of challenges, but nothing prepared me for the day I had to make the painful decision to throw away 20,000 products. I’m sharing this story not just for my customers but also for fellow small business owners who might find themselves in a similar position.

My first product, the Twinkle Moment Instant Dry Sink Caddy, launched in Dark Gray—a versatile, stain-resistant shade that blended seamlessly into kitchens and bathrooms. As the business grew, I listened to customer feedback and saw a demand for a lighter gray option. In December 2024, I started developing what would become the Glacier Gray sink caddy—a modern, fresh color designed to suit sleek kitchen aesthetics.

Everything seemed to be going well. I worked with my manufacturer to refine the shade, ensuring it had the same durability and fast-drying performance as the original. But then, when I reviewed the first batch of samples, I noticed something strange. The carved airflow design on the tray wasn’t as seamless as it should be. The recessed areas appeared slightly darker, disrupting the clean, uniform look I had envisioned.

This might not seem like a big deal to some, but for me, it was. Customers were trusting me to deliver a high-quality, beautifully designed product, and I couldn’t ignore something that made the product look unfinished. I immediately contacted the manufacturer, and they assured me the issue could be fixed. They promised that any products with this flaw would be classified as defective and would not be shipped.

To make sure I caught any problems early, I set up two rounds of inspections—one before packaging and another after. I documented everything through online conversations, emails, and videos. I felt confident that I had done everything I could to ensure a perfect product.

Then came the day of final production. I sent an inspector to check the products before they were packed. When the photos and videos arrived, my heart sank. The same issue was still there. The carved sections still looked darkened, exactly as they had in the samples. The factory had completely ignored my instructions.

I felt a wave of panic. 20,000 units of my product were now sitting in a warehouse, fully produced, waiting to be shipped. My stomach dropped as I realized the weight of the situation. If I rejected the products, I would be walking away from months of effort, a huge financial investment, and my entire launch schedule. If I accepted them, I’d be selling a product that didn’t meet my standards.

At first, I tried everything to salvage the situation. I asked if there was a way to correct the issue after production—maybe a different finishing process or a new coating technique. But the manufacturer wasn’t offering solutions. They simply wanted me to accept the flawed products and move on.

This was one of the hardest decisions I’ve ever made. I had already announced the upcoming launch to my customers. I had already envisioned the Glacier Gray sink caddy becoming a staple in so many homes. But I knew that if I compromised on quality now, I would regret it later.

After sleepless nights and countless discussions with the manufacturer, I made my final decision: I would scrap the entire production.

This week, I shared one of the biggest challenges I’ve faced as a small business owner—having to scrap 20,000 products due to a manufacturing issue. It was a tough decision, but the story doesn’t end here. Next week, I’ll share how I tackled this setback, found a new manufacturer, and finally brought Glacier Gray to life. Stay tuned!

Stella Seong