Case Study: Custom Kids Aviator Hat for a Corporate Procurement Team in Ireland

Kids Aviator Hat for a Corporate Procurement Team in Ireland

A Corporate Procurement Team approached us with a kids aviator hat requirement for Ireland. 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

• Color drift between lab dips and bulk fabric
• Inconsistent sizing between production runs
• Suppliers who disappear once the deposit is paid

What we specified

How it was resolved

1. We rebuilt the tech pack around Rayon and locked shrinkage allowance before grading.
2. Decoration was moved to Satin Printed Label 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

• 2,000 pieces delivered inside the 8-week window.
• Unit cost held within 1.5% 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?

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