Case Study: Custom Zipper Guard for a Theatre Costume Workshop in Mexico
Source:Straight Hair Bulk /
Time:2026-09-18
Zipper Guard for a Theatre Costume Workshop in Mexico
A Theatre Costume Workshop approached us with a zipper guard requirement for the Mexico 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
- A compliance document that arrived after the goods were already shipped
- Elastic that lost recovery after three washes
What we specified
| Item | Zipper Guard |
|---|---|
| Client type | A Theatre Costume Workshop |
| Market | Mexico |
| Order volume | 20,000 pieces across 2 specifications |
| Base material | Silicone |
| Standard size | 6 mm Width |
| Finish | Antique Brass Plating |
| Sampling rounds | 3 |
| Delivery window | 10 weeks from PO to ex-factory |
| Compliance | RoHS |
How it was resolved
- We rebuilt the specification around Silicone and locked the tolerance before bulk.
- The finish was moved to Matte Black Coating 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 10-week window.
- Unit cost held within 2.0% 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
Keep one accountable owner on both sides. Most delays come from hand-offs, not from machines.
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.
