Case Study: Custom Grey Baseball Cap for a Brewery and Taproom in the United Kingdom

Grey Baseball Cap for a Brewery and Taproom in the United Kingdom

A Brewery and Taproom approached us with a grey baseball cap requirement for the United Kingdom. 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
• Minimum order quantities far above what a growing brand can absorb
• Inconsistent sizing between production runs

What we specified

How it was resolved

1. We rebuilt the tech pack around Nylon and locked shrinkage allowance before grading.
2. Decoration was moved to Quilting 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

• 1,200 pieces delivered inside the 5-week window.
• Unit cost held within 4.5% 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

Lock the colour standard before grading. Once a shade moves, every downstream approval has to be redone and the calendar slips.

Planning something similar?

Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.