Case Study: Custom Flannel Fabric for a Workwear Distributor in Ukraine
Source:Nylon Satin Ribbon /
Time:2026-09-18
Flannel Fabric for a Workwear Distributor in Ukraine
A Workwear Distributor approached us with a flannel fabric requirement for the Ukraine 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
- Elastic that lost recovery after three washes
- An interlining that bubbled after the first press
- Reorders that quietly changed supplier and changed the hand feel
What we specified
| Item | Flannel Fabric |
|---|---|
| Client type | A Workwear Distributor |
| Market | Ukraine |
| Order volume | 5,000 pieces across 4 specifications |
| Base material | Aluminium |
| Standard size | 140 gsm |
| Finish | Nickel-Free Electroplating |
| Sampling rounds | 4 |
| Delivery window | 6 weeks from PO to ex-factory |
| Compliance | California Prop 65 |
How it was resolved
- We rebuilt the specification around Aluminium and locked the tolerance before bulk.
- The finish was moved to Black Nickel 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
- 5,000 pieces delivered inside the 6-week window.
- Unit cost held within 4.5% 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?
Share the programme details and we will propose two alternatives — one optimised for unit cost, one for lead time — and let you choose.
