Case Study: Custom Eco-Friendly Wetsuit for a Yoga Retreat Brand in Portugal

Eco-Friendly Wetsuit for a Yoga Retreat Brand in Portugal

A Yoga Retreat Brand approached us with a eco-friendly wetsuit 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

• Suppliers who disappear once the deposit is paid
• Unclear responsibility when a defect shows up after washing
• Packaging that arrives crushed and unsellable

What we specified

How it was resolved

1. We rebuilt the tech pack around Cotton-Poly Blend and locked shrinkage allowance before grading.
2. Decoration was moved to Seam Sealing 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

• 5,000 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

Approve a pre-production sample from the actual bulk fabric. Proto cloth behaves differently in cutting and washing.

Planning something similar?

Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.