Case Study: Custom Polyester Fabric for a Hospital Procurement Team in Ireland

Polyester Fabric for a Hospital Procurement Team in Ireland

A Hospital Procurement Team approached us with a polyester fabric requirement for the Ireland 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 zipper puller that broke under pull test at the warehouse
• A trim that passed sampling but failed in-line because it was never cycle tested
• A spec that lived in an email instead of a tech pack

What we specified

How it was resolved

1. We rebuilt the specification around Cotton and locked the tolerance before bulk.
2. The finish was moved to Soft-Touch Rubber Coating 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

• 10,000 pieces delivered inside the 6-week window.
• Unit cost held within 3.0% of the original quotation.
• Inspection-related rejection stayed under 2.0%.
• 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?

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.