Custom Boonie in Merino Wool with Padding and Wadding

Custom Boonie — Merino Wool with Padding and Wadding

We build boonie programmes from a tech pack or a physical reference sample. This Merino Wool version is developed for brands that need a repeatable specification: the same cloth, the same hand feel and the same fit on every reorder. Fabric, trims, padding and wadding and packaging are all specifiable, so the garment stays consistent across seasons and across production runs.

Most buyers come to us after one of these problems: no reliable way to track a order once it enters production, or no reliable way to track a order once it enters production. Our response is to fix the specification first — fabric weight, shrinkage allowance, stitch density and tolerance — before a single bulk metre is cut.

Specification

What you can customise

• Enzyme Wash — available on Merino Wool, quoted per position and per colour.
• Ultrasonic Welding — available on Merino Wool, quoted per position and per colour.
• Smocking — available on Merino Wool, quoted per position and per colour.
• Quilting — available on Merino Wool, quoted per position and per colour.
• Hangtag and Packaging — available on Merino Wool, quoted per position and per colour.
• All-Over Sublimation — available on Merino Wool, quoted per position and per colour.
• Chenille Embroidery — available on Merino Wool, quoted per position and per colour.

How we produce it

1. Tech pack review and fabric confirmation
2. Lab dips or print strike-off for approval
3. Pattern making, grading and a Merino Wool-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with padding and wadding applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Golf Clubs — boonie uniforms, staff wear or resale programmes
• Beauty and Cosmetics — boonie uniforms, staff wear or resale programmes
• Fashion Brands and Labels — boonie uniforms, staff wear or resale programmes
• Religious and Community — boonie uniforms, staff wear or resale programmes
• Sports Teams and Clubs — boonie uniforms, staff wear or resale programmes

Quality control

Every bulk order is checked against the approved sample for shade, hand feel, measurements and workmanship. We record shrinkage, colour fastness and seam strength on the first bulk lot and hold the data as the reference for reorders, so boonie batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.

FAQ

What file formats do you need for artwork?

Vector files (AI, EPS, PDF) give the best print and embroidery results. For raster artwork please supply at least 300 dpi at the final print size. We digitise embroidery files in-house and return a sew-out photo for approval.

How long does sampling take?

A first prototype is typically ready in 12 working days after the tech pack is confirmed, including fabric sourcing if the base cloth is not in our stock library. Revisions add about 5 days each.

What is the minimum order quantity?

Standard programmes start at 300 pieces per style and colour. We can split sizes across a size set, and for first orders we often accept a mixed-colour run to help you test the market.

Do you provide compliance documents?

We can arrange OEKO-TEX, GOTS, BSCI, WRAP and ISO documentation as well as third-party testing reports for ISO 9001, and we support REACH, CPSIA and Prop 65 declarations for the relevant markets.

Start your boonie programme

Book a 20-minute call with our merchandising team and get a written quotation within 48 hours.