Case Studies

Real Projects. Real Results.

Every project below is a real order from a real retailer. Challenge, solution, results — no fluff, no vanity metrics.

Boohoo

Hoodies & Sweatshirts

50,000+ units 28 days

C Challenge

Boohoo needed 50,000 premium fleece hoodies across 6 colourways delivered within 28 days for their Autumn/Winter drop. Previous supplier had inconsistent GSM across colourways, causing fit issues in-store.

S Solution

We sourced a single dye-lot per colourway from our GOTS-certified dyeing partner, ensuring GSM consistency within ±5g. Dedicated production line with in-line weight checks every 2 hours. Pre-production size set approved in 7 days.

R Results

Zero quality rejections across all 3 seasonal orders
GSM variance reduced to ±3g (industry standard: ±10g)
28-day turnaround maintained across all 3 orders
Extended to sweatshirts and joggers in Season 2

Fleece6 ColourwaysZero Rejections3 Seasons

Yours Clothing

Ladies' Knitwear

75,000+ units 35 days

C Challenge

Yours Clothing required consistent fit grading from XS to 5XL across 12 styles of ladies' knitwear. Extended sizing is notoriously difficult — small measurement deviations become very visible at larger sizes.

S Solution

Our pattern team developed a proprietary grading matrix calibrated specifically for the UK plus-size market. Each size was fit-tested on real body forms, not just scaled up. Pre-production samples included every size for approval.

R Results

Consistent fit grading across XS–5XL, 12 styles
0.3% defect rate (5× better than AQL 2.5)
2+ year ongoing partnership with expanding order volumes
Reduced their sample approval cycle from 21 to 14 days

Extended SizingXS–5XL12 Styles2-Year Partnership

CLOSURE

Premium T-Shirts

30,000+ units 25 days

C Challenge

CLOSURE needed organic cotton t-shirts with custom all-over prints and branded neck labels for a limited drop. The timeline was tight — 25 days from approval to delivery, with no room for reprints.

S Solution

Pre-allocated organic cotton fabric from our BCI-certified stock. Digital printing set up within 48 hours of artwork approval. Branded woven labels produced in parallel. Rush production line with priority QC.

R Results

Delivered 5 days ahead of schedule
All 30,000 units passed AQL 2.5 first time
Custom print colour accuracy: ΔE < 1.5
Reorder placed within 8 weeks of delivery

Organic CottonCustom PrintEarly DeliveryRush Order

Pull & Bear

Joggers & Trousers

40,000+ units 30 days

C Challenge

Pull & Bear required 40,000 joggers with elastic waistbands and drawcords. The critical issue was waistband elasticity consistency — previous batches from another supplier had 12% failure rate on elastic recovery.

S Solution

Sourced premium Lycra-blend elastic from a certified elastane supplier. Developed a custom elastic recovery test: 1000 stretch cycles at 150% extension before production sign-off. In-line elasticity test every 100 units.

R Results

Elastic recovery failure rate: 0.2% (was 12% with previous supplier)
All 40,000 units delivered on time
Waistband measurement tolerance: ±0.5cm across all sizes
Seasonal reorder confirmed for next 2 drops

JoggersElastic TestingLycra BlendSeasonal

Daisy Street

Crop Tops & Bralettes

25,000+ units 22 days

C Challenge

Daisy Street needed fast-turnaround crop tops and bralettes across 8 colourways for a trend-responsive drop. The challenge was maintaining colour consistency across 8 dye lots while hitting a 22-day deadline.

S Solution

Used our in-house colour matching lab with spectrophotometer verification. All 8 dye lots matched to ΔE < 1.0 (industry standard: ΔE < 2.0). Parallel production across 3 stitching lines to compress timeline.

R Results

22-day turnaround on 8 colourways
Colour consistency: ΔE < 1.0 across all lots
0.4% defect rate
Ongoing orders now placed monthly

Fast Fashion8 ColourwaysColour MatchingMonthly Orders

Threadbare

Polo Shirts

60,000+ units 32 days

C Challenge

Threadbare required 60,000 polo shirts with collar shaping that held its structure after 50 washes. Collar roll and curl after washing is the #1 complaint in polo manufacturing.

S Solution

Developed a fused collar construction with proprietary interlining. Tested collar structure through 50 industrial wash cycles (ISO 6330) before production approval. Collar shaping reinforced with hidden bar-tacks.

R Results

Zero collar roll complaints after 50 wash cycles
60,000 units delivered across 7 colourways
Secured annual supply contract
Design adopted as their new collar standard

PolosCollar Engineering50-Wash TestAnnual Contract

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