Case Study: Custom Toggle Button for a Sportswear Brand in Ireland
Source:Palette Knife Oil Painting /
Time:2026-09-18
Toggle Button for a Sportswear Brand in Ireland
A Sportswear Brand approached us with a toggle button requirement for the Ireland 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
- Cartons packed to the factory ratio instead of the buyer's size ratio
- An interlining that bubbled after the first press
- Lead time quoted without the plating or dyeing sub-process
What we specified
| Item | Toggle Button |
|---|---|
| Client type | A Sportswear Brand |
| Market | Ireland |
| Order volume | 10,000 pieces across 4 specifications |
| Base material | POM Plastic |
| Standard size | 9 mm Width |
| Finish | Antique Brass Plating |
| Sampling rounds | 2 |
| Delivery window | 10 weeks from PO to ex-factory |
| Compliance | ISO 9001 |
How it was resolved
- We rebuilt the specification around POM Plastic and locked the tolerance before bulk.
- The finish was moved to Gunmetal 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
- 10,000 pieces delivered inside the 10-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.
