Case Study: Custom Cropped Denim Dungarees for a Gym Chain in Italy
Source:Cropped Denim Dungarees /
Time:2026-09-18
Cropped Denim Dungarees for a Gym Chain in Italy
A Gym Chain approached us with a cropped denim dungarees requirement for Italy. 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
- Packaging that arrives crushed and unsellable
- Long lead times that miss the selling season
What we specified
| Product | Cropped Denim Dungarees |
|---|---|
| Client type | A Gym Chain |
| Market | Italy |
| Order volume | 2,000 pieces across 3 colourways |
| Base fabric | Pique Knit |
| Decoration | Piping and Binding |
| Size range | Custom grading |
| Sampling rounds | 2 |
| Delivery window | 12 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Pique Knit and locked shrinkage allowance before grading.
- Decoration was moved to Piping and Binding 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
- 2,000 pieces delivered inside the 12-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?
Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.
