Case Study: Custom Reverse Coil Zipper for a Theatre Costume Workshop in Austria
Source:Silk Sunflower Decor /
Time:2026-09-18
Reverse Coil Zipper for a Theatre Costume Workshop in Austria
A Theatre Costume Workshop approached us with a reverse coil zipper requirement for the Austria 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
- An interlining that bubbled after the first press
- Cartons packed to the factory ratio instead of the buyer's size ratio
- A spec that lived in an email instead of a tech pack
What we specified
| Item | Reverse Coil Zipper |
|---|---|
| Client type | A Theatre Costume Workshop |
| Market | Austria |
| Order volume | 2,000 pieces across 4 specifications |
| Base material | Nickel Silver |
| Standard size | 6 mm Width |
| Finish | Epoxy Doming |
| Sampling rounds | 2 |
| Delivery window | 10 weeks from PO to ex-factory |
| Compliance | CPSIA |
How it was resolved
- We rebuilt the specification around Nickel Silver and locked the tolerance before bulk.
- The finish was moved to Laser Engraved 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
- 2,000 pieces delivered inside the 10-week window.
- Unit cost held within 3.0% 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
Approve a pre-production sample made from the actual bulk base material. Substitute material behaves differently in finishing.
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.
