Case Study: Custom Wooden Button for a Hotel Group in Egypt
Source:Embroidered Patch Badges /
Time:2026-09-18
Wooden Button for a Hotel Group in Egypt
A Hotel Group approached us with a wooden button requirement for the Egypt 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
- Elastic that lost recovery after three washes
- Cartons packed to the factory ratio instead of the buyer's size ratio
What we specified
| Item | Wooden Button |
|---|---|
| Client type | A Hotel Group |
| Market | Egypt |
| Order volume | 5,000 pieces across 3 specifications |
| Base material | Nylon |
| Standard size | 38 mm Width |
| Finish | Anodised Finish |
| Sampling rounds | 4 |
| Delivery window | 8 weeks from PO to ex-factory |
| Compliance | WRAP |
How it was resolved
- We rebuilt the specification around Nylon and locked the tolerance before bulk.
- The finish was moved to Matte Black Coating 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
- 5,000 pieces delivered inside the 8-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
Keep one accountable owner on both sides. Most delays come from hand-offs, not from machines.
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.
