Case Study: Custom Flannel Fabric for a Craft Wholesaler in Egypt
Source:Embroidered Patch Badges /
Time:2026-09-18
Flannel Fabric for a Craft Wholesaler in Egypt
A Craft Wholesaler approached us with a flannel fabric requirement for the Egypt 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 spec that lived in an email instead of a tech pack
- MOQ that was quoted per colourway rather than per style
- An interlining that bubbled after the first press
What we specified
| Item | Flannel Fabric |
|---|---|
| Client type | A Craft Wholesaler |
| Market | Egypt |
| Order volume | 20,000 pieces across 4 specifications |
| Base material | Acrylic |
| Standard size | 180 gsm |
| Finish | Black Nickel Finish |
| Sampling rounds | 3 |
| Delivery window | 10 weeks from PO to ex-factory |
| Compliance | California Prop 65 |
How it was resolved
- We rebuilt the specification around Acrylic and locked the tolerance before bulk.
- The finish was moved to UV Printing 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 3.0% of the original quotation.
- Inspection-related rejection stayed under 1.0%.
- 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?
Tell us the item, the quantity and the delivery window. We will quote it with the sub-processes named, so the lead time you approve is the lead time you get.
