Case Study: Custom Tailored Denim Suit for a Cycling Team in Ireland
Source:Tailored Denim Suit /
Time:2026-09-18
Tailored Denim Suit for a Cycling Team in Ireland
A Cycling Team approached us with a tailored denim suit 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
- Unclear responsibility when a defect shows up after washing
- No reliable way to track a order once it enters production
What we specified
| Product | Tailored Denim Suit |
|---|---|
| Client type | A Cycling Team |
| Market | Ireland |
| Order volume | 2,000 pieces across 2 colourways |
| Base fabric | Suede |
| Decoration | Contrast Stitching |
| Size range | Custom grading |
| Sampling rounds | 4 |
| Delivery window | 6 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Suede and locked shrinkage allowance before grading.
- Decoration was moved to Contrast Stitching 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 6-week window.
- Unit cost held within 2.0% 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?
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.
