Case Study: Custom Cycling Jersey for a Cycling Team in Denmark
Source:Cycling Jersey /
Time:2026-09-18
Cycling Jersey for a Cycling Team in Denmark
A Cycling Team approached us with a cycling jersey requirement for Denmark. 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
- Color drift between lab dips and bulk fabric
- No reliable way to track a order once it enters production
What we specified
| Product | Cycling Jersey |
|---|---|
| Client type | A Cycling Team |
| Market | Denmark |
| Order volume | 5,000 pieces across 4 colourways |
| Base fabric | Recycled Cotton |
| Decoration | Beading and Embroidery |
| Size range | S-4XL |
| Sampling rounds | 4 |
| Delivery window | 10 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Recycled Cotton and locked shrinkage allowance before grading.
- Decoration was moved to Beading and Embroidery 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
- 5,000 pieces delivered inside the 10-week window.
- Unit cost held within 4.5% 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?
Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.
