Case Study: Custom Zipper Guard for a Bag and Luggage Maker in Denmark
Source:Electronic Device Lanyard /
Time:2026-09-18
Zipper Guard for a Bag and Luggage Maker in Denmark
A Bag and Luggage Maker approached us with a zipper guard requirement for the Denmark 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
- A zipper puller that broke under pull test at the warehouse
- MOQ that was quoted per colourway rather than per style
What we specified
| Item | Zipper Guard |
|---|---|
| Client type | A Bag and Luggage Maker |
| Market | Denmark |
| Order volume | 10,000 pieces across 6 specifications |
| Base material | POM Plastic |
| Standard size | 9 mm Width |
| Finish | Soft-Touch Rubber Coating |
| Sampling rounds | 3 |
| Delivery window | 8 weeks from PO to ex-factory |
| Compliance | WRAP |
How it was resolved
- We rebuilt the specification around POM Plastic and locked the tolerance before bulk.
- The finish was moved to Silicone Wash 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 8-week window.
- Unit cost held within 3.0% 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
Keep one accountable owner on both sides. Most delays come from hand-offs, not from machines.
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.
