Case Study: Custom Recycled Polyester Fabric for a Theatre Costume Workshop in New Zealand

Recycled Polyester Fabric for a Theatre Costume Workshop in New Zealand

A Theatre Costume Workshop approached us with a recycled polyester fabric requirement for the New Zealand 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
• Elastic that lost recovery after three washes
• MOQ that was quoted per colourway rather than per style

What we specified

How it was resolved

1. We rebuilt the specification around Genuine Leather and locked the tolerance before bulk.
2. The finish was moved to Glossy Enamel Coating after strike-off tests showed better durability.
3. A pre-production sample was approved and retained as the golden reference.
4. Production ran with in-line inspection and a mid-run photo report.
5. Cartons were packed to the client's own barcode and ratio specification.

Result

• 5,000 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

Keep one accountable owner on both sides. Most delays come from hand-offs, not from machines.

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.