Case Study: Custom Grey Baseball Cap for a Mining Company in New Zealand
Source:Grey Baseball Cap /
Time:2026-09-18
Grey Baseball Cap for a Mining Company in New Zealand
A Mining Company approached us with a grey baseball cap requirement for New Zealand. 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
- No reliable way to track a order once it enters production
- Inconsistent sizing between production runs
What we specified
| Product | Grey Baseball Cap |
|---|---|
| Client type | A Mining Company |
| Market | New Zealand |
| Order volume | 500 pieces across 2 colourways |
| Base fabric | Cupro |
| Decoration | Heat Transfer Printing |
| Size range | S-4XL |
| Sampling rounds | 3 |
| Delivery window | 5 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Cupro and locked shrinkage allowance before grading.
- Decoration was moved to Heat Transfer 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
- 500 pieces delivered inside the 5-week window.
- Unit cost held within 3.0% 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
Keep one process owner on both sides. Most delays come from hand-offs, not from machines.
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.
