Case Study: Custom Invisible Zipper for a Bag and Luggage Maker in Japan
Source:Mixed Floral Arrangements /
Time:2026-09-18
Invisible Zipper for a Bag and Luggage Maker in Japan
A Bag and Luggage Maker approached us with a invisible zipper requirement for the Japan 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
- Lead time quoted without the plating or dyeing sub-process
- Shrinkage that only showed up after the first wash
- An interlining that bubbled after the first press
What we specified
| Item | Invisible Zipper |
|---|---|
| Client type | A Bag and Luggage Maker |
| Market | Japan |
| Order volume | 100,000 pieces across 6 specifications |
| Base material | Glass |
| Standard size | 5# Gauge |
| Finish | Brushed Silver Finish |
| Sampling rounds | 3 |
| Delivery window | 10 weeks from PO to ex-factory |
| Compliance | ISO 14001 |
How it was resolved
- We rebuilt the specification around Glass 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
- 100,000 pieces delivered inside the 10-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
Approve a pre-production sample made from the actual bulk base material. Substitute material behaves differently in finishing.
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.
