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.

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.