Case Study: Custom Corduroy Fabric for a Hat and Cap Producer in South Korea
Source:Coir Plant Mats /
Time:2026-09-18
Corduroy Fabric for a Hat and Cap Producer in South Korea
A Hat and Cap Producer approached us with a corduroy fabric requirement for the South Korea 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 trim that passed sampling but failed in-line because it was never cycle tested
- Elastic that lost recovery after three washes
- An interlining that bubbled after the first press
What we specified
| Item | Corduroy Fabric |
|---|---|
| Client type | A Hat and Cap Producer |
| Market | South Korea |
| Order volume | 2,000 pieces across 2 specifications |
| Base material | Zinc Alloy |
| Standard size | 80 gsm |
| Finish | Epoxy Doming |
| Sampling rounds | 2 |
| Delivery window | 6 weeks from PO to ex-factory |
| Compliance | JIS L Standards |
How it was resolved
- We rebuilt the specification around Zinc Alloy and locked the tolerance before bulk.
- The finish was moved to Rose Gold Plating 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 6-week window.
- Unit cost held within 4.5% 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
Fix the specification count early. Adding variants after production starts is the most expensive change a client can request.
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.
