Case Study: Custom Winter Leg Warmers for a Professional Sports Club in Thailand
Source:Winter Leg Warmers /
Time:2026-09-18
Winter Leg Warmers for a Professional Sports Club in Thailand
A Professional Sports Club approached us with a winter leg warmers requirement for Thailand. 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
- Long lead times that miss the selling season
- Packaging that arrives crushed and unsellable
- Minimum order quantities far above what a growing brand can absorb
What we specified
| Product | Winter Leg Warmers |
|---|---|
| Client type | A Professional Sports Club |
| Market | Thailand |
| Order volume | 1,200 pieces across 6 colourways |
| Base fabric | Merino Wool |
| Decoration | Distressed Finish |
| Size range | 2-12Y |
| Sampling rounds | 2 |
| Delivery window | 12 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Merino Wool and locked shrinkage allowance before grading.
- Decoration was moved to Distressed Finish 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 12-week window.
- Unit cost held within 1.5% 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
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.
