Case Study: Custom Cord Lock for an Airline Catering Supplier in Denmark
Source:Old World Maps /
Time:2026-09-18
Cord Lock for an Airline Catering Supplier in Denmark
An Airline Catering Supplier approached us with a cord lock 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
- Shrinkage that only showed up after the first wash
- Lead time quoted without the plating or dyeing sub-process
- An interlining that bubbled after the first press
What we specified
| Item | Cord Lock |
|---|---|
| Client type | An Airline Catering Supplier |
| Market | Denmark |
| Order volume | 10,000 pieces across 6 specifications |
| Base material | Acrylic |
| Standard size | 8# Gauge |
| Finish | Pearlescent Coating |
| Sampling rounds | 2 |
| Delivery window | 6 weeks from PO to ex-factory |
| Compliance | ISO 105 Colour Fastness |
How it was resolved
- We rebuilt the specification around Acrylic and locked the tolerance before bulk.
- The finish was moved to Enzyme 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 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
Fix the specification count early. Adding variants after production starts is the most expensive change a client can request.
Planning something similar?
Send the reference sample or tech pack and we will come back with a costed specification, a sampling timetable and the compliance documents your market requires.
