Case Study: Custom Cycling Jersey for a Construction Firm in the United States
Source:Cycling Jersey /
Time:2026-09-18
Cycling Jersey for a Construction Firm in the United States
A Construction Firm approached us with a cycling jersey requirement for the United States. 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
- Unclear responsibility when a defect shows up after washing
What we specified
| Product | Cycling Jersey |
|---|---|
| Client type | A Construction Firm |
| Market | the United States |
| Order volume | 5,000 pieces across 6 colourways |
| Base fabric | Faux Leather PU |
| Decoration | Piping and Binding |
| Size range | XS-3XL |
| Sampling rounds | 4 |
| Delivery window | 8 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Faux Leather PU 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
- 5,000 pieces delivered inside the 8-week window.
- Unit cost held within 3.0% of the original quotation.
- Return rate linked to fit or workmanship stayed under 0.5%.
- The specification is now on file, so reorders reproduce the approved sample.
What we would repeat
Lock the colour standard before grading. Once a shade moves, every downstream approval has to be redone and the calendar slips.
Planning something similar?
Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.
