Case Study: Custom Ripstop Nylon Fabric for a Lingerie Specialist in Belgium

Ripstop Nylon Fabric for a Lingerie Specialist in Belgium

A Lingerie Specialist approached us with a ripstop nylon fabric requirement for the Belgium 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

• A zipper puller that broke under pull test at the warehouse
• Lead time quoted without the plating or dyeing sub-process
• Cartons packed to the factory ratio instead of the buyer's size ratio

What we specified

How it was resolved

1. We rebuilt the specification around Zinc Alloy and locked the tolerance before bulk.
2. The finish was moved to Powder Coating after strike-off tests showed better durability.
3. A pre-production sample was approved and retained as the golden reference.
4. Production ran with in-line inspection and a mid-run photo report.
5. 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 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

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.