Case Study: Custom Felt Fabric for an Airline Catering Supplier in Brazil
Source:Indoor Fountain Design /
Time:2026-09-18
Felt Fabric for an Airline Catering Supplier in Brazil
An Airline Catering Supplier approached us with a felt fabric requirement for the Brazil 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
- Reorders that quietly changed supplier and changed the hand feel
- An interlining that bubbled after the first press
- Shade drift between the approved lab dip and the bulk lot
What we specified
| Item | Felt Fabric |
|---|---|
| Client type | An Airline Catering Supplier |
| Market | Brazil |
| Order volume | 100,000 pieces across 2 specifications |
| Base material | Rubber |
| Standard size | 210 gsm |
| Finish | Chrome Plating |
| Sampling rounds | 4 |
| Delivery window | 4 weeks from PO to ex-factory |
| Compliance | RoHS |
How it was resolved
- We rebuilt the specification around Rubber and locked the tolerance before bulk.
- The finish was moved to Epoxy Doming 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
- 100,000 pieces delivered inside the 4-week window.
- Unit cost held within 3.0% 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?
Send the reference sample or tech pack and we will come back with a costed specification, a sampling timetable and the compliance documents your market requires.
