Case Study: Custom Grommet for a Hat and Cap Producer in Peru
Source:Antique Hand Painted Screen /
Time:2026-09-18
Grommet for a Hat and Cap Producer in Peru
A Hat and Cap Producer approached us with a grommet requirement for the Peru 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
- Cartons packed to the factory ratio instead of the buyer's size ratio
- Elastic that lost recovery after three washes
- A spec that lived in an email instead of a tech pack
What we specified
| Item | Grommet |
|---|---|
| Client type | A Hat and Cap Producer |
| Market | Peru |
| Order volume | 10,000 pieces across 3 specifications |
| Base material | ABS Resin |
| Standard size | 12 mm Width |
| Finish | Antique Copper Finish |
| Sampling rounds | 2 |
| Delivery window | 6 weeks from PO to ex-factory |
| Compliance | CPSIA |
How it was resolved
- We rebuilt the specification around ABS Resin 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
- 10,000 pieces delivered inside the 6-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
Fix the specification count early. Adding variants after production starts is the most expensive change a client can request.
Planning something similar?
Send the reference sample or tech pack and we will come back with a costed specification, a sampling timetable and the compliance documents your market requires.
