Case Study: Custom Jacquard Webbing for a Hat and Cap Producer in Portugal
Source:Digital Picture Frames /
Time:2026-09-18
Jacquard Webbing for a Hat and Cap Producer in Portugal
A Hat and Cap Producer approached us with a jacquard webbing requirement for the Portugal 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
- Elastic that lost recovery after three washes
- A zipper puller that broke under pull test at the warehouse
What we specified
| Item | Jacquard Webbing |
|---|---|
| Client type | A Hat and Cap Producer |
| Market | Portugal |
| Order volume | 50,000 pieces across 3 specifications |
| Base material | ABS Resin |
| Standard size | 10# Gauge |
| Finish | Rose Gold Plating |
| Sampling rounds | 2 |
| Delivery window | 5 weeks from PO to ex-factory |
| Compliance | AATCC Test Methods |
How it was resolved
- We rebuilt the specification around ABS Resin and locked the tolerance before bulk.
- The finish was moved to Silicone Wash 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
- 50,000 pieces delivered inside the 5-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
Approve a pre-production sample made from the actual bulk base material. Substitute material behaves differently in finishing.
Planning something similar?
Share the programme details and we will propose two alternatives — one optimised for unit cost, one for lead time — and let you choose.
