Case Study: Custom Viscose Fabric for a Hat and Cap Producer in Spain
Source:Metal Lapel Pins /
Time:2026-09-18
Viscose Fabric for a Hat and Cap Producer in Spain
A Hat and Cap Producer approached us with a viscose fabric requirement for the Spain 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
- An interlining that bubbled after the first press
- Elastic that lost recovery after three washes
- A trim that passed sampling but failed in-line because it was never cycle tested
What we specified
| Item | Viscose Fabric |
|---|---|
| Client type | A Hat and Cap Producer |
| Market | Spain |
| Order volume | 100,000 pieces across 3 specifications |
| Base material | Stainless Steel |
| Standard size | 80 gsm |
| Finish | Enzyme Wash Finish |
| Sampling rounds | 4 |
| Delivery window | 4 weeks from PO to ex-factory |
| Compliance | ISO 9001 |
How it was resolved
- We rebuilt the specification around Stainless Steel 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
- 100,000 pieces delivered inside the 4-week window.
- Unit cost held within 4.5% 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
Lock the material standard before sampling. Once the base changes, every downstream approval has to be redone and the calendar slips.
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.
