Case Study: Custom Silicone Patch for a Theatre Costume Workshop in the United Kingdom

Silicone Patch for a Theatre Costume Workshop in the United Kingdom

A Theatre Costume Workshop approached us with a silicone patch requirement for the the United Kingdom 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

• MOQ that was quoted per colourway rather than per style
• Shrinkage that only showed up after the first wash
• A compliance document that arrived after the goods were already shipped

What we specified

How it was resolved

1. We rebuilt the specification around POM Plastic and locked the tolerance before bulk.
2. The finish was moved to Laser Engraved Finish 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

• 100,000 pieces delivered inside the 10-week window.
• Unit cost held within 2.0% 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

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.