Case Study: Custom Two-Tone Flip Sequins for a Hospital Group in Canada

Two-Tone Flip Sequins for a Hospital Group in Canada

A Hospital Group approached us with a two-tone flip sequins requirement for Canada. 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
• Inconsistent sizing between production runs
• No reliable way to track a order once it enters production

What we specified

How it was resolved

1. We rebuilt the tech pack around Ring-Spun Cotton and locked shrinkage allowance before grading.
2. Decoration was moved to Dye-Sublimation 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 6-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?

Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.