Case Study: Custom Flannel Fabric for a Lingerie Specialist in the Philippines
Source:Dry Fountain Nozzles /
Time:2026-09-18
Flannel Fabric for a Lingerie Specialist in the Philippines
A Lingerie Specialist approached us with a flannel fabric requirement for the the Philippines 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
- Shrinkage that only showed up after the first wash
- Reorders that quietly changed supplier and changed the hand feel
- A zipper puller that broke under pull test at the warehouse
What we specified
| Item | Flannel Fabric |
|---|---|
| Client type | A Lingerie Specialist |
| Market | the Philippines |
| Order volume | 20,000 pieces across 4 specifications |
| Base material | ABS Resin |
| Standard size | 140 gsm |
| Finish | Chrome Plating |
| Sampling rounds | 3 |
| Delivery window | 6 weeks from PO to ex-factory |
| Compliance | ISO 14001 |
How it was resolved
- We rebuilt the specification around ABS Resin and locked the tolerance before bulk.
- The finish was moved to Sandblasted 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 6-week window.
- Unit cost held within 2.0% of the original quotation.
- Inspection-related rejection stayed under 1.5%.
- The specification is now on file, so reorders reproduce the approved sample.
What we would repeat
Keep one accountable owner on both sides. Most delays come from hand-offs, not from machines.
Planning something similar?
If you are comparing suppliers, send us the spec they quoted against. We will quote the same spec and show you where the difference sits.
