Case Study: Custom Unisex Outdoor Cap for a Promotional Products Company in Portugal
Source:Unisex Outdoor Cap /
Time:2026-09-18
Unisex Outdoor Cap for a Promotional Products Company in Portugal
A Promotional Products Company approached us with a unisex outdoor cap requirement for Portugal. 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
- Minimum order quantities far above what a growing brand can absorb
- Long lead times that miss the selling season
What we specified
| Product | Unisex Outdoor Cap |
|---|---|
| Client type | A Promotional Products Company |
| Market | Portugal |
| Order volume | 2,000 pieces across 4 colourways |
| Base fabric | Linen |
| Decoration | Shirring |
| Size range | 2-12Y |
| Sampling rounds | 4 |
| Delivery window | 12 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Linen and locked shrinkage allowance before grading.
- Decoration was moved to Shirring 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
- 2,000 pieces delivered inside the 12-week window.
- Unit cost held within 3.0% 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?
Book a 20-minute call with our merchandising team and get a written quotation within 48 hours.
