Case Study: Custom Invisible Zipper for a Hat and Cap Producer in Chile
Source:Fashion Lanyard /
Time:2026-09-18
Invisible Zipper for a Hat and Cap Producer in Chile
A Hat and Cap Producer approached us with a invisible zipper requirement for the Chile 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
- A spec that lived in an email instead of a tech pack
- Elastic that lost recovery after three washes
What we specified
| Item | Invisible Zipper |
|---|---|
| Client type | A Hat and Cap Producer |
| Market | Chile |
| Order volume | 100,000 pieces across 6 specifications |
| Base material | PU Leather |
| Standard size | 38 mm Width |
| Finish | UV Printing |
| Sampling rounds | 2 |
| Delivery window | 10 weeks from PO to ex-factory |
| Compliance | GB 18401 |
How it was resolved
- We rebuilt the specification around PU Leather 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 10-week window.
- Unit cost held within 1.5% of the original quotation.
- Inspection-related rejection stayed under 0.5%.
- 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?
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.
