Case Study: Custom Multi Station Gym Fitness Set for a Hotel Group in Portugal
Source:Multi Station Gym Fitness Set /
Time:2026-09-18
Multi Station Gym Fitness Set for a Hotel Group in Portugal
A Hotel Group approached us with a multi station gym fitness set requirement for Portugal. 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
- Inconsistent sizing between production runs
- Packaging that arrives crushed and unsellable
- No reliable way to track a order once it enters production
What we specified
| Product | Multi Station Gym Fitness Set |
|---|---|
| Client type | A Hotel Group |
| Market | Portugal |
| Order volume | 5,000 pieces across 2 colourways |
| Base fabric | Interlock Knit |
| Decoration | Glow-in-the-Dark Printing |
| Size range | Custom grading |
| Sampling rounds | 2 |
| Delivery window | 5 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Interlock Knit and locked shrinkage allowance before grading.
- Decoration was moved to Glow-in-the-Dark 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
- 5,000 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 0.5%.
- 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.
