Case Study: Custom Stretch Denim Fabric for a Footwear Factory in New Zealand
Source:Polished Gem Beads /
Time:2026-09-18
Stretch Denim Fabric for a Footwear Factory in New Zealand
A Footwear Factory approached us with a stretch denim fabric requirement for the New Zealand 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
- Reorders that quietly changed supplier and changed the hand feel
- A spec that lived in an email instead of a tech pack
- Lead time quoted without the plating or dyeing sub-process
What we specified
| Item | Stretch Denim Fabric |
|---|---|
| Client type | A Footwear Factory |
| Market | New Zealand |
| Order volume | 50,000 pieces across 3 specifications |
| Base material | Nylon |
| Standard size | 320 gsm |
| Finish | Anodised Finish |
| Sampling rounds | 3 |
| Delivery window | 5 weeks from PO to ex-factory |
| Compliance | RoHS |
How it was resolved
- We rebuilt the specification around Nylon and locked the tolerance before bulk.
- The finish was moved to Piece-Dyed 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 3.0% 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
Lock the material standard before sampling. Once the base changes, every downstream approval has to be redone and the calendar slips.
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.
