Case Study: Custom Shell Button for a Uniform Supplier in Ireland
Source:Waterproof Matte Labels /
Time:2026-09-18
Shell Button for a Uniform Supplier in Ireland
A Uniform Supplier approached us with a shell button requirement for the Ireland market. The brief was specific: a defined look, a hard launch date and a unit cost that had to survive freight and duty. This case study records what was specified, what went wrong in sampling and how the bulk order was delivered.
The challenge
- Elastic that lost recovery after three washes
- Shade drift between the approved lab dip and the bulk lot
- Lead time quoted without the plating or dyeing sub-process
What we specified
| Item | Shell Button |
|---|---|
| Client type | A Uniform Supplier |
| Market | Ireland |
| Order volume | 20,000 pieces across 3 specifications |
| Base material | Iron |
| Standard size | 5# Gauge |
| Finish | Matte Black Coating |
| Sampling rounds | 4 |
| Delivery window | 4 weeks from PO to ex-factory |
| Compliance | ISO 9001 |
How it was resolved
- We rebuilt the specification around Iron and locked the tolerance before bulk.
- The finish was moved to Laser Engraved Finish after strike-off tests showed better 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 ratio specification.
Result
- 20,000 pieces delivered inside the 4-week window.
- Unit cost held within 2.0% of the original quotation.
- Inspection-related rejection 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 made from the actual bulk base material. Substitute material behaves differently in finishing.
Planning something similar?
Tell us the item, the quantity and the delivery window. We will quote it with the sub-processes named, so the lead time you approve is the lead time you get.
