Case Study: Custom Cycling Short for an Airline Catering Team in Portugal

Cycling Short for an Airline Catering Team in Portugal

An Airline Catering Team approached us with a cycling short requirement for Portugal. 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
• Suppliers who disappear once the deposit is paid
• Unclear responsibility when a defect shows up after washing

What we specified

How it was resolved

1. We rebuilt the tech pack around Faux Shearling and locked shrinkage allowance before grading.
2. Decoration was moved to Yarn Dyeing after strike-off tests showed better wash durability.
3. A pre-production sample was approved and retained as the golden reference.
4. Production ran with in-line inspection and a mid-run photo report.
5. Cartons were packed to the client's own barcode and size ratio specification.

Result

• 1,200 pieces delivered inside the 5-week window.
• Unit cost held within 4.5% 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

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.