CAP PRODUCTION PROCESS EXPOSED

Step 1
Fabrics

Most fabrics used for hats and caps are made of 100% cotton. A twill construction is most commonly used and the fabrics come in a great variety of constructions. However, Polyester, acrylic, wool as well as mixes of these yarns are also used.

To give the fabrics that extra softness we use various degrees of brushing. All fabrics have been re-active dyed to avoid colour bleeding. Upon finish the fabrics will be transported from the mill to the hats & caps factory.

Classic baseball cap

6 panels cap, inner seam tape, pre-curved visor...	6 panels cap, inner seam tape, pre-curved visor...	6 panels cap, inner seam tape, pre-curved visor...
6 panels cap, inner seam tape, pre-curved visor...	6 panels cap, inner seam tape, pre-curved visor...	6 panels cap, inner seam tape, pre-curved visor...
6 panels cap, inner seam tape, pre-curved visor...	6 panels cap, inner seam tape, pre-curved visor...	6 panels cap, inner seam tape, pre-curved visor...

Step 2

 Cutting of fabrics

The fabrics will be placed on the cutting table in layers and markers made for each hat panel will be placed on top of the fabric pile. The top fabric layer is marked and the fabrics are then cut by a handheld or fixed electric saw. There might be very slight variations in the dyeing lots, therefore, it is important that the cutting room keeps a track of the panels that have been cut to avoid any color shading of the hat.

Step 3

Decoration

For embroidery we use new Tajima embroidery machines, printing is silk screen printing using imported inks and badges are made by factories using Taiwanese technology and equipment. Whereas the front panels of the hat is a normal position for any decoration, nowadays you often see decoration on the side and back of the hat, on straps and on the top or ottom of the peak.

Step 4

Assembling

The decorated panels will be passed to the sewing lines for stitching the panels and peak together and generally assemble the hat with sweatband, strap/closing, top button and
sewn-on labels.

There are a great variety of closings to choose from like Velcro, plastic snaps, zippers and metal buckles. And the peaks come in different sizes and shapes including the per-curved peak which has been popular for a few years now.

 Step 5

Finishing

Quality Control

The hats are passed to the finishing section where the loose sewing threads will be cut off and the quality control section will inspect the finished products. Upon completion the hats will be shaped using a hot mold and then packed.

Step7

Packaging

We can pack according to the customer's requirement, but most exports are standard factory packing which is 2 dozen in a poly bag and inner box, then 144pcs per export carton.
The standard carton gross weight is approx 15kgs, net weight is 13kgs and the carton dimensions are approx. 61x41x51 cm. If you like this article don’t forget to subscribe and follow our Blog. Don’t forget to share this post via various social media sites.