Case Study: Custom Silk Bonnet for a Mining Company in Colombia

Silk Bonnet for a Mining Company in Colombia

A Mining Company approached us with a silk bonnet requirement for Colombia. 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
• Unclear responsibility when a defect shows up after washing
• Inconsistent sizing between production runs

What we specified

How it was resolved

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

• 500 pieces delivered inside the 6-week window.
• Unit cost held within 2.0% 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

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.