Case Study: Custom Pongee Fabric for a Workwear Distributor in Spain
Source:Old World Maps /
Time:2026-09-18
Pongee Fabric for a Workwear Distributor in Spain
A Workwear Distributor approached us with a pongee fabric requirement for the Spain 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
- Shade drift between the approved lab dip and the bulk lot
- Elastic that lost recovery after three washes
- Lead time quoted without the plating or dyeing sub-process
What we specified
| Item | Pongee Fabric |
|---|---|
| Client type | A Workwear Distributor |
| Market | Spain |
| Order volume | 2,000 pieces across 6 specifications |
| Base material | Genuine Leather |
| Standard size | 360 gsm |
| Finish | Glossy Enamel Coating |
| Sampling rounds | 3 |
| Delivery window | 4 weeks from PO to ex-factory |
| Compliance | OEKO-TEX Standard 100 |
How it was resolved
- We rebuilt the specification around Genuine Leather and locked the tolerance before bulk.
- The finish was moved to Antique Copper 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 4-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.
