Case Study: Custom Plus Size Equestrian Clothing for a Cycling Team in Ireland

Plus Size Equestrian Clothing for a Cycling Team in Ireland

A Cycling Team approached us with a plus size equestrian clothing requirement for Ireland. 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
• Suppliers who disappear once the deposit is paid
• No reliable way to track a order once it enters production

What we specified

How it was resolved

1. We rebuilt the tech pack around Eyelet and locked shrinkage allowance before grading.
2. Decoration was moved to Hangtag and Packaging 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

• 800 pieces delivered inside the 6-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

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.