Case Study: Custom Cotton Golf Cap for a Security Company in Ireland
Source:Cotton Golf Cap /
Time:2026-09-18
Cotton Golf Cap for a Security Company in Ireland
A Security Company approached us with a cotton golf 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
- Suppliers who disappear once the deposit is paid
- Packaging that arrives crushed and unsellable
- Inconsistent sizing between production runs
What we specified
| Product | Cotton Golf Cap |
|---|---|
| Client type | A Security Company |
| Market | Ireland |
| Order volume | 1,200 pieces across 2 colourways |
| Base fabric | Stretch Denim |
| Decoration | Screen Printing |
| Size range | S-4XL |
| Sampling rounds | 4 |
| Delivery window | 12 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Stretch Denim and locked shrinkage allowance before grading.
- Decoration was moved to Screen 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
- 1,200 pieces delivered inside the 12-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
Fix the size ratio early. Changing the ratio after cutting starts is the single most expensive change a client can request.
Planning something similar?
Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.
