Case Study: Custom Corduroy Fabric for a Footwear Factory in Italy
Source:Pastel Flag Banner /
Time:2026-09-18
Corduroy Fabric for a Footwear Factory in Italy
A Footwear Factory approached us with a corduroy fabric requirement for the Italy 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
- Reorders that quietly changed supplier and changed the hand feel
- Cartons packed to the factory ratio instead of the buyer's size ratio
- A zipper puller that broke under pull test at the warehouse
What we specified
| Item | Corduroy Fabric |
|---|---|
| Client type | A Footwear Factory |
| Market | Italy |
| Order volume | 5,000 pieces across 2 specifications |
| Base material | Ceramic |
| Standard size | 360 gsm |
| Finish | Matte Black Coating |
| Sampling rounds | 4 |
| Delivery window | 6 weeks from PO to ex-factory |
| Compliance | ISO 105 Colour Fastness |
How it was resolved
- We rebuilt the specification around Ceramic and locked the tolerance before bulk.
- The finish was moved to Gunmetal 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 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?
Share the programme details and we will propose two alternatives — one optimised for unit cost, one for lead time — and let you choose.
