Case Study: Custom Blue Down Jacket for a Coffee Roaster Chain in Israel
Source:Blue Down Jacket /
Time:2026-09-18
Blue Down Jacket for a Coffee Roaster Chain in Israel
A Coffee Roaster Chain approached us with a blue down jacket requirement for Israel. The brief was specific: a defined look, a hard launch date and a unit cost that had to survive shipping and duty. This case study records what was specified, what went wrong in sampling and how the bulk order was delivered.
The challenge
- No reliable way to track a order once it enters production
- Inconsistent sizing between production runs
- Suppliers who disappear once the deposit is paid
What we specified
| Product | Blue Down Jacket |
|---|---|
| Client type | A Coffee Roaster Chain |
| Market | Israel |
| Order volume | 1,200 pieces across 3 colourways |
| Base fabric | Recycled Nylon |
| Decoration | Satin Printed Label |
| Size range | Custom grading |
| Sampling rounds | 3 |
| Delivery window | 6 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Recycled Nylon and locked shrinkage allowance before grading.
- Decoration was moved to Satin Printed Label after strike-off tests showed better wash durability.
- A pre-production sample was approved and retained as the golden reference.
- Production ran with in-line inspection and a mid-run photo report.
- Cartons were packed to the client's own barcode and size ratio specification.
Result
- 1,200 pieces delivered inside the 6-week window.
- Unit cost held within 4.5% of the original quotation.
- Return rate linked to fit or workmanship stayed under 2.0%.
- The specification is now on file, so reorders reproduce the approved sample.
What we would repeat
Fix the size ratio early. Changing the ratio after cutting starts is the single most expensive change a client can request.
Planning something similar?
Send us your tech pack or even a rough sketch — we will come back with fabric options, a costed sample plan and a realistic production calendar.
