Case Study: Custom Open-End Zipper for a Craft Wholesaler in Australia
Source:Party Costume /
Time:2026-09-18
Open-End Zipper for a Craft Wholesaler in Australia
A Craft Wholesaler approached us with a open-end zipper requirement for the Australia 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
- Lead time quoted without the plating or dyeing sub-process
- Cartons packed to the factory ratio instead of the buyer's size ratio
What we specified
| Item | Open-End Zipper |
|---|---|
| Client type | A Craft Wholesaler |
| Market | Australia |
| Order volume | 10,000 pieces across 2 specifications |
| Base material | Cotton |
| Standard size | 5# Gauge |
| Finish | Soft-Touch Rubber Coating |
| Sampling rounds | 3 |
| Delivery window | 5 weeks from PO to ex-factory |
| Compliance | BSCI |
How it was resolved
- We rebuilt the specification around Cotton and locked the tolerance before bulk.
- The finish was moved to Mercerised 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
- 10,000 pieces delivered inside the 5-week window.
- Unit cost held within 3.0% of the original quotation.
- Inspection-related rejection stayed under 1.5%.
- The specification is now on file, so reorders reproduce the approved sample.
What we would repeat
Keep one accountable owner on both sides. Most delays come from hand-offs, not from machines.
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.
