Case Study: Custom Melton Wool Fabric for a Theatre Costume Workshop in Ukraine
Source:Hand Carved Stone Vase /
Time:2026-09-18
Melton Wool Fabric for a Theatre Costume Workshop in Ukraine
A Theatre Costume Workshop approached us with a melton wool fabric requirement for the Ukraine 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
- MOQ that was quoted per colourway rather than per style
- Elastic that lost recovery after three washes
What we specified
| Item | Melton Wool Fabric |
|---|---|
| Client type | A Theatre Costume Workshop |
| Market | Ukraine |
| Order volume | 20,000 pieces across 3 specifications |
| Base material | Zinc Alloy |
| Standard size | 180 gsm |
| Finish | Rose Gold Plating |
| Sampling rounds | 4 |
| Delivery window | 8 weeks from PO to ex-factory |
| Compliance | RoHS |
How it was resolved
- We rebuilt the specification around Zinc Alloy 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
- 20,000 pieces delivered inside the 8-week window.
- Unit cost held within 4.5% of the original quotation.
- Inspection-related rejection stayed under 1.0%.
- 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?
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.
