Case Study: UltraLiteSacks
UltraLiteSacks Finds a Scalable U.S. Manufacturing Partner with DustyShore.
Client Profile
Company: UltraLiteSacks
Industry: Outdoor Gear & Ultralight Equipment
Headquarters: Arkansas
Primary Needs: Contract cutting, scalable production, regional fulfillment
Logistics Preference: Manufacturing partner within 4 hours of operations
Background
UltraLiteSacks is a fast-growing outdoor gear company known for high-performance ultralight products. As demand increased, the leadership team recognized the need to reshuffle their production model toward a U.S.-based contract manufacturing solution. Their goals were clear:
Relocate production closer to home
Start lean with cutting services
Scale to full production and fulfillment over time
Partner with a facility that understands performance-grade textiles
UltraLiteSacks turned to DustyShores, a reshoring consultancy specializing in helping brands move manufacturing operations to the United States.
The Challenge
The challenge was two-fold:
Geographic Limitation: The facility needed to be within a 4-hour radius of UltraLiteSacks’ HQ to ensure fast shipping, in-person collaboration, and efficient oversight.
Scalability & Expertise: The chosen manufacturer required initial cutting capabilities, as well as the infrastructure and expertise to support full-scope production and fulfillment down the line.
DustyShores’ Approach
DustyShores, led by Caden Gennerman, deployed its Reshore Readiness Methodology, which includes:
Vendor Mapping: Shortlisting U.S.-based contract manufacturers in technical textiles and soft goods.
Capability Matching: Verifying equipment, capacity, and production track record aligned with UltraLiteSacks’ quality and growth needs.
Logistics Scoring: Evaluating travel times, freight networks, and communication responsiveness.
Hands-on Vetting: Conducting facility reviews, owner/operator calls, and site visit coordination.
The Outcome
DustyShores delivered a U.S. manufacturing solution that exceeded UltraLiteSacks' expectations:
✅ Located 30 Minutes from UltraLiteSacks HQ
✅ Equipped for high-precision contract cutting of lightweight technical fabrics
✅ Built-in room for expansion into sewing, assembly, and fulfillment services
✅ Clear line of communication with ownership and floor supervisors
Client Testimonial
“DustyShores has been a valuable partner for UltraLiteSacks. We sought an American contract manufacturer capable of scaling with our brand. We wanted to start with contract cutting, progressing to full production and fulfillment as needed. Our primary logistical requirement was a location within a four-hour drive.
Caden and the DustyShores team surpassed our expectations. They identified a manufacturing partner perfectly suited to manage our immediate needs, while offering substantial capacity for future growth. Notably, this facility is conveniently located less than 30 minutes from our operations.
We extend our highest recommendation for Caden and DustyShores. Their service is excellent, they are highly responsive, and their expertise in this field is truly valuable.”
— UltraLiteSacks CEO
Key Results
MetricResultProximity to Operations< 30 minutesTime to First Cut Order< 3 weeks after partner selectionExpansion CapabilityFull production + fulfillment readyCommunication Score (Client)“Highly responsive & insightful”
