Case Study: Custom Unisex Outdoor Cap for a Restaurant Chain in New Zealand
Source:Unisex Outdoor Cap /
Time:2026-09-18
Unisex Outdoor Cap for a Restaurant Chain in New Zealand
A Restaurant Chain approached us with a unisex outdoor cap requirement for New Zealand. 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
- Unclear responsibility when a defect shows up after washing
- 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 Restaurant Chain |
| Market | New Zealand |
| Order volume | 500 pieces across 4 colourways |
| Base fabric | Selvedge Denim |
| Decoration | DTG Digital Printing |
| Size range | S-4XL |
| Sampling rounds | 3 |
| Delivery window | 6 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Selvedge Denim and locked shrinkage allowance before grading.
- Decoration was moved to DTG Digital 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
- 500 pieces delivered inside the 6-week window.
- Unit cost held within 4.5% 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?
Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.
