Manufacturing Cap Process
Once all details of the cap sample are confirmed, we proceed to the production of the cap.
We can detail this manufacturing process in several steps.
Cutting of fabric
We purchase with our fabric supplier the quantity of fabric needed. Once arrived in our factory, our fabric’s department checks the quality/quantity and compares the color to the sample or Pre-production sample. a) If there isn’t color variance, we proceed to step 2 b) If there is color variance, we always show to customer for approval.
For information, the color variance is due to the difference of rolls of fabric which have been produced at different time from the fabric supplier. In other words, the fabric that we bought to make sample and the fabric that we bought for bulk order don’t come from the same roll produced. For little color variance, most of time, customer use to accept it because it would extend the production time, excepted in the case where the color variance is too big, we return to fabric roll to vendor. Either we ask another roll, either we look for another swatch card .
Once the fabric is confirmed, our fabric department will proceed to cutting. The cutting consists in bending the fabric in several layers and uses a press machine to compress with an iron mold. For each shape of hat, we use different iron mold.
This step is to prepare the fabric for sewing and customization part. Then, we have the fabric in panels of the cap crown and the fabric for the visor ready.
All the steps are not linear. Some custom parts which don’t need the fabric are executed from the beginning like print taping, print sweatband, print lining, print sweatband label, print washing label, embossing/debossing leather or metal badge, indeed whatever the custom option chosen of the cap which are independent of the fabric cutting.
For each custom echnique, we have 2 or 3 regular suppliers to insure the quality and the speed. We only make embroideries in house. We have 12 Barudan and Tajima embroidery machines and 2 small one for embroidery of samples. All are working H24 with 3 different teams.
For the customizations made by our suppliers, our merchandisers follow the progress to avoid any delay and coordinate the timing with the assembly of the caps. At last, merchandiser checks the quality of customizations compared to the sample once back to our cap factory before fixing them on the cap.
Sewing and assembly of the cap
We have approximately 300 sewing machines organized into four production lines. Our production manager organizes the cap orders to be sewn in each line every week, and posts the tasks for each worker on a large whiteboard. Each production line also has a chief to ensure the continuity of production and fulfill the hat orders. Our team of over 300 skilled workers can produce about 200k pieces per month.
We can detail all the small tasks to make a cap in each production line as follows:
Add buckram on the two front panels
(link to https://www.youtube.com/watch?v=ebsU5CNQ15w&feature=relmfu)
Sew the plastic brim with the fabric
Stitch the above part of the brim of the cap circularly
(link to https://www.youtube.com/watch?v=YySYSStZzmU&feature=youtu.be)
Sew the different panels to form the crown
(link to https://www.youtube.com/watch?v=YHK35xK5xFg&feature=youtu.be)
Seam the tape between each panel inside the crown
Sew the brim with the crown of the cap
(link to https://www.youtube.com/watch?v=5lNbCAaimAE&feature=relmfu)
Sew the sweatband at the back bottom of the crown
Sew the interior washing label
Sew the inside label on the sweatband
Sew the crown with the visor
Stitch the eyelets of each panel
(link to https://www.youtube.com/watch?v=5lNbCAaimAE&feature=relmfu)
Stitch at the bottom of the crown and the border of each panels
Sew the closure Add the top button
Above are just the main tasks, not the complete production tasks. We have much more small tasks amdit depends on the style of the hat.After we assemble the cap, we clean the interior and the exterior by cutting all the extra-threads and clean the cap with air jet.
Then we can process to the blocking steam machine to get the perfect shape.
Shape of the cap
We have 4 productions lines to insure the continuity of the manufacturing cap process and the fast turnaround. This step consists in getting the final shape of the cap once we assemble the panels, visor, sweatband, taping, and closure. We use a cap blocking steam machine which allows to wet the cap from inside through a iron head with plenty of hole where get through the very high degree steam, and at the same time to block the crown of the cap thanks to a puller down during a few seconds. Then, our workers in charge of steaming check the shape and place the cap on the conveyor belt which allow cooling down the caps with some fans blowing under the conveyor belt. Of course, each hape of the cap requires a different iron head.
We refer to this video to understand the steaming and blocking process of the cap in order to get the wanted shape.
Worker blocking cap shape
Different steam Blocking molds for each shape
Cleaning and packaging
Then, caps slide down to a long big table on which others workers QC by comparing with the proto-sample, then others workers cut extra-threads, put the pre-made custom trims like printed polybags, customized hangtags,product barcode stickers, plastic hok… and clean again with powerful air jet.
In the end, packaging workers put them, according to the packing instructions of customer, in inner cartons, then master cartons pre-printed with style number, name, gross weight, net weight, dimension and ready to ship to customers.
As you see, we have a very detailed procedure for manufacturing high-end headwear. We have several levels of quality control which allow us to assure our superior quality compared to others competitors which all pretend premium. We are not the cheapest, but If you are looking for high-end custom headwear, we really recommend you to test an order with us to see that we are a top professional hat manufacturer.
A detail very important of our quality that is not common in Chinese factories: our managing staff at different levels and sewing workers are, most of us, the same every year after Chinese New Year, because we treat everyone well fairly, financially and humanly as we consider everyone as a family. Every worker knows the level of quality that all customer requires. This can really insure the same quality of the headwear all the year whereas many factories need to train new workers again especially just after Chinese New Year.
As conclusion, all the production line of our manufacturing process is very safe and smooth in order to produce the cap bulk order same as samples, whereas most of competitors can’t control quality same as sample. This is really our superiority compared to our competitors! As said again, do not hesitate to try one bulk order and you will see the difference between us and our competitors.
Cutting border of panels
Hole of Eyelets
Sewing Visor 2
Manufacturing cap process