Case Study: Custom Plus Size Arm Shaper for a Gym Chain in Morocco
Source:Plus Size Arm Shaper /
Time:2026-09-18
Plus Size Arm Shaper for a Gym Chain in Morocco
A Gym Chain approached us with a plus size arm shaper requirement for Morocco. 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
- No reliable way to track a order once it enters production
- Unclear responsibility when a defect shows up after washing
- Minimum order quantities far above what a growing brand can absorb
What we specified
| Product | Plus Size Arm Shaper |
|---|---|
| Client type | A Gym Chain |
| Market | Morocco |
| Order volume | 3,000 pieces across 4 colourways |
| Base fabric | Recycled Polyester (rPET) |
| Decoration | Garment Dyeing |
| Size range | 2-12Y |
| Sampling rounds | 3 |
| Delivery window | 8 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Recycled Polyester (rPET) and locked shrinkage allowance before grading.
- Decoration was moved to Garment Dyeing 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
- 3,000 pieces delivered inside the 8-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
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.
