Case Study: Custom Polar Fleece Fabric for a Theatre Costume Workshop in South Korea
Source:Party Costume /
Time:2026-09-18
Polar Fleece Fabric for a Theatre Costume Workshop in South Korea
A Theatre Costume Workshop approached us with a polar fleece fabric requirement for the South Korea 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
- Lead time quoted without the plating or dyeing sub-process
- An interlining that bubbled after the first press
- MOQ that was quoted per colourway rather than per style
What we specified
| Item | Polar Fleece Fabric |
|---|---|
| Client type | A Theatre Costume Workshop |
| Market | South Korea |
| Order volume | 10,000 pieces across 4 specifications |
| Base material | Zinc Alloy |
| Standard size | 320 gsm |
| Finish | Silicone Wash Finish |
| Sampling rounds | 2 |
| Delivery window | 4 weeks from PO to ex-factory |
| Compliance | OEKO-TEX Standard 100 |
How it was resolved
- We rebuilt the specification around Zinc Alloy and locked the tolerance before bulk.
- The finish was moved to Yarn-Dyed 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
- 10,000 pieces delivered inside the 4-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
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.
