Case Study: Custom Unisex Outdoor Cap for a Security Company in Portugal

Unisex Outdoor Cap for a Security Company in Portugal

A Security Company approached us with a unisex outdoor cap requirement for Portugal. 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
• Minimum order quantities far above what a growing brand can absorb
• 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 Interlock Knit and locked shrinkage allowance before grading.
2. Decoration was moved to Rhinestone Application 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

• 500 pieces delivered inside the 8-week window.
• Unit cost held within 2.0% of the original quotation.
• Return rate linked to fit or workmanship stayed under 2.0%.
• 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.