Case Study: Custom Special Forces Tactical Vest for a Coffee Roaster Chain in Ireland

Special Forces Tactical Vest for a Coffee Roaster Chain in Ireland

A Coffee Roaster Chain approached us with a special forces tactical vest 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

• Minimum order quantities far above what a growing brand can absorb
• No reliable way to track a order once it enters production
• Suppliers who disappear once the deposit is paid

What we specified

How it was resolved

1. We rebuilt the tech pack around Faux Shearling and locked shrinkage allowance before grading.
2. Decoration was moved to Placement 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

• 800 pieces delivered inside the 10-week window.
• Unit cost held within 3.0% 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

Lock the colour standard before grading. Once a shade moves, every downstream approval has to be redone and the calendar slips.

Planning something similar?

Send us your tech pack or even a rough sketch — we will come back with fabric options, a costed sample plan and a realistic production calendar.