Case Study: Custom Silk Bonnet for a Coffee Roaster Chain in China
Source:Silk Bonnet /
Time:2026-09-18
Silk Bonnet for a Coffee Roaster Chain in China
A Coffee Roaster Chain approached us with a silk bonnet requirement for China. 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
- Long lead times that miss the selling season
- Inconsistent sizing between production runs
- No reliable way to track a order once it enters production
What we specified
| Product | Silk Bonnet |
|---|---|
| Client type | A Coffee Roaster Chain |
| Market | China |
| Order volume | 3,000 pieces across 6 colourways |
| Base fabric | Cotton-Poly Blend |
| Decoration | Acid Wash |
| Size range | XS-3XL |
| Sampling rounds | 4 |
| Delivery window | 8 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Cotton-Poly Blend and locked shrinkage allowance before grading.
- Decoration was moved to Acid Wash 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 2.0% 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
Keep one process owner on both sides. Most delays come from hand-offs, not from machines.
Planning something similar?
Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.
