Case Study: Custom Quick Dry Surf Rash Guard for a Boutique Fitness Studio in New Zealand
Source:Quick Dry Surf Rash Guard /
Time:2026-09-18
Quick Dry Surf Rash Guard for a Boutique Fitness Studio in New Zealand
A Boutique Fitness Studio approached us with a quick dry surf rash guard 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
- Suppliers who disappear once the deposit is paid
- Packaging that arrives crushed and unsellable
- Long lead times that miss the selling season
What we specified
| Product | Quick Dry Surf Rash Guard |
|---|---|
| Client type | A Boutique Fitness Studio |
| Market | New Zealand |
| Order volume | 5,000 pieces across 2 colourways |
| Base fabric | Denim |
| Decoration | Pleating |
| Size range | XS-3XL |
| Sampling rounds | 3 |
| Delivery window | 10 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Denim and locked shrinkage allowance before grading.
- Decoration was moved to Pleating 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 10-week window.
- Unit cost held within 4.5% 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
Approve a pre-production sample from the actual bulk fabric. Proto cloth behaves differently in cutting and washing.
Planning something similar?
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