Case Study: Custom Unisex Outdoor Cap for a Security Company in Saudi Arabia
Source:Unisex Outdoor Cap /
Time:2026-09-18
Unisex Outdoor Cap for a Security Company in Saudi Arabia
A Security Company approached us with a unisex outdoor cap requirement for Saudi Arabia. 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
- Color drift between lab dips and bulk fabric
- No reliable way to track a order once it enters production
What we specified
| Product | Unisex Outdoor Cap |
|---|---|
| Client type | A Security Company |
| Market | Saudi Arabia |
| Order volume | 1,200 pieces across 4 colourways |
| Base fabric | Satin |
| Decoration | DTF Film Printing |
| Size range | Custom grading |
| Sampling rounds | 4 |
| 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 DTF Film Printing 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
- 1,200 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 1.5%.
- 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?
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.
