Case Study: Custom Plus Size 3/4 Sleeve Tunic for a Public School District in Ireland
Source:Plus Size 3/4 Sleeve Tunic /
Time:2026-09-18
Plus Size 3/4 Sleeve Tunic for a Public School District in Ireland
A Public School District approached us with a plus size 3/4 sleeve tunic 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
- Packaging that arrives crushed and unsellable
What we specified
| Product | Plus Size 3/4 Sleeve Tunic |
|---|---|
| Client type | A Public School District |
| Market | Ireland |
| Order volume | 5,000 pieces across 6 colourways |
| Base fabric | Alpaca |
| Decoration | Custom Button |
| Size range | 2-12Y |
| Sampling rounds | 2 |
| Delivery window | 8 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Alpaca and locked shrinkage allowance before grading.
- Decoration was moved to Custom Button 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 1.0%.
- The specification is now on file, so reorders reproduce the approved sample.
What we would repeat
Keep one process owner on both sides. Most delays come from hand-offs, not from machines.
Planning something similar?
Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.
