Case Study: Custom Unisex Outdoor Cap for a Surf School in China
Source:Unisex Outdoor Cap /
Time:2026-09-18
Unisex Outdoor Cap for a Surf School in China
A Surf School approached us with a unisex outdoor cap requirement for China. 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
- Color drift between lab dips and bulk fabric
- Inconsistent sizing between production runs
- Minimum order quantities far above what a growing brand can absorb
What we specified
| Product | Unisex Outdoor Cap |
|---|---|
| Client type | A Surf School |
| Market | China |
| Order volume | 2,000 pieces across 3 colourways |
| Base fabric | Ring-Spun Cotton |
| Decoration | Glow-in-the-Dark Printing |
| Size range | 2-12Y |
| Sampling rounds | 3 |
| Delivery window | 12 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Ring-Spun Cotton and locked shrinkage allowance before grading.
- Decoration was moved to Glow-in-the-Dark 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
- 2,000 pieces delivered inside the 12-week window.
- Unit cost held within 4.5% 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
Keep one process owner on both sides. Most delays come from hand-offs, not from machines.
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.
