Case Study: Custom Cropped Denim Dungarees for a Surf School in France

Cropped Denim Dungarees for a Surf School in France

A Surf School approached us with a cropped denim dungarees requirement for France. 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
• Long lead times that miss the selling season
• Minimum order quantities far above what a growing brand can absorb

What we specified

How it was resolved

1. We rebuilt the tech pack around Power Mesh and locked shrinkage allowance before grading.
2. Decoration was moved to Tie-Dye Wash 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

• 800 pieces delivered inside the 6-week window.
• Unit cost held within 1.5% of the original quotation.
• Return rate linked to fit or workmanship stayed under 1.0%.
• 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?

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.