Case Study: Custom Softball Pitcher Cap for a Surf School in Spain

Softball Pitcher Cap for a Surf School in Spain

A Surf School approached us with a softball pitcher cap requirement for Spain. 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
• Packaging that arrives crushed and unsellable
• Unclear responsibility when a defect shows up after washing

What we specified

How it was resolved

1. We rebuilt the tech pack around Wool Blend and locked shrinkage allowance before grading.
2. Decoration was moved to Rhinestone Application 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

• 500 pieces delivered inside the 6-week window.
• Unit cost held within 2.0% of the original quotation.
• Return rate linked to fit or workmanship stayed under 1.0%.
• 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?

Send us your tech pack or even a rough sketch — we will come back with fabric options, a costed sample plan and a realistic production calendar.