Case Study: Custom Boys' Denim Varsity Jacket for a Professional Sports Club in Hong Kong
Source:Boys' Denim Varsity Jacket /
Time:2026-09-18
Boys' Denim Varsity Jacket for a Professional Sports Club in Hong Kong
A Professional Sports Club approached us with a boys' denim varsity jacket requirement for Hong Kong. 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
- Packaging that arrives crushed and unsellable
- No reliable way to track a order once it enters production
- Inconsistent sizing between production runs
What we specified
| Product | Boys' Denim Varsity Jacket |
|---|---|
| Client type | A Professional Sports Club |
| Market | Hong Kong |
| Order volume | 1,200 pieces across 6 colourways |
| Base fabric | Polyester |
| Decoration | Bonding Construction |
| Size range | 2-12Y |
| Sampling rounds | 4 |
| Delivery window | 12 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Polyester and locked shrinkage allowance before grading.
- Decoration was moved to Bonding Construction 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 12-week window.
- Unit cost held within 1.5% of the original quotation.
- Return rate linked to fit or workmanship stayed under 1.5%.
- The specification is now on file, so reorders reproduce the approved sample.
What we would repeat
Approve a pre-production sample from the actual bulk fabric. Proto cloth behaves differently in cutting and washing.
Planning something similar?
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