Case Study: Custom Unisex Outdoor Cap for a Coffee Roaster Chain in Ireland
Source:Unisex Outdoor Cap /
Time:2026-09-18
Unisex Outdoor Cap for a Coffee Roaster Chain in Ireland
A Coffee Roaster Chain approached us with a unisex outdoor cap 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
- Color drift between lab dips and bulk fabric
- No reliable way to track a order once it enters production
- Long lead times that miss the selling season
What we specified
| Product | Unisex Outdoor Cap |
|---|---|
| Client type | A Coffee Roaster Chain |
| Market | Ireland |
| Order volume | 5,000 pieces across 2 colourways |
| Base fabric | Tencel Lyocell |
| Decoration | Laser Cutting |
| Size range | S-4XL |
| Sampling rounds | 3 |
| Delivery window | 10 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Tencel Lyocell and locked shrinkage allowance before grading.
- Decoration was moved to Laser Cutting 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 4.5% 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
Keep one process owner on both sides. Most delays come from hand-offs, not from machines.
Planning something similar?
Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.
