Case Study: Custom Plus Size Arm Shaper for an Airline Catering Team in Russia
Source:Plus Size Arm Shaper /
Time:2026-09-18
Plus Size Arm Shaper for an Airline Catering Team in Russia
An Airline Catering Team approached us with a plus size arm shaper requirement for Russia. 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
- Inconsistent sizing between production runs
- Suppliers who disappear once the deposit is paid
- Unclear responsibility when a defect shows up after washing
What we specified
| Product | Plus Size Arm Shaper |
|---|---|
| Client type | An Airline Catering Team |
| Market | Russia |
| Order volume | 8,000 pieces across 3 colourways |
| Base fabric | Brushed Fleece |
| Decoration | Beading and Embroidery |
| Size range | 2-12Y |
| Sampling rounds | 2 |
| Delivery window | 5 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Brushed Fleece and locked shrinkage allowance before grading.
- Decoration was moved to Beading and Embroidery 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
- 8,000 pieces delivered inside the 5-week window.
- Unit cost held within 1.5% 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
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.
