Case Study: Custom Sleeping Bonnet for a Kidswear Subscription Box in Ireland
Source:Sleeping Bonnet /
Time:2026-09-18
Sleeping Bonnet for a Kidswear Subscription Box in Ireland
A Kidswear Subscription Box approached us with a sleeping bonnet 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
- Inconsistent sizing between production runs
- Unclear responsibility when a defect shows up after washing
- Suppliers who disappear once the deposit is paid
What we specified
| Product | Sleeping Bonnet |
|---|---|
| Client type | A Kidswear Subscription Box |
| Market | Ireland |
| Order volume | 5,000 pieces across 3 colourways |
| Base fabric | Satin |
| Decoration | Beading and Embroidery |
| Size range | Custom grading |
| Sampling rounds | 2 |
| Delivery window | 10 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Satin 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
- 5,000 pieces delivered inside the 10-week window.
- Unit cost held within 2.0% 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
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.
