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.
Step 1: Find suitable raw materials. Joysport will you find out materials the same or similar to samples (in case, Chinese market do not have materials you want). The our norm of material selection always ensure eastheticism, similar, quality with reasonable price and others (button-hole, lock, peak, thread) all make the product not only good but also equal about details.
Step 2: We hand over all the details to the machine, and part of it will be handed over to the staff
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. Cutting of fabric. All the cap components are of the same shape and size for most of the caps and thus hydraulic machines are mostly used to cut the panels.
B. Stitching process of the crown and visor. They can start simultaneously as they are made separately and attached before the final process. The stitching starts with the front panels first through the SNLS machine. Often due to cap design, another layer of fusing fabric is added to the back of the front panel. This gives the raised shape to the crown.
C. Embroidery on the panels. After this, the front panel is sent to the embroidery department where distinct logos and graphics are embroidered onto the front panels through computerized embroidery machines.
D. Attach eyelets on the panels. After embroidery, the panels are sent to eyelet machines where the machine pierces through the panel and stitch around its edges.
E. Attach tapes. With most of the caps being 6-paneled caps the stitching starts with stitching 3 panels together twice which is stitched in between and reversed to form the crown. These tapes ensure that the seams give a soft feel to the wearer at the seams.
F. Make the visor part. Alongside the crown, the front visor is made by stitching two fabric panes like a pocket and turning it inside out. The material to be put inside the visor can range from stiff fabric to plastic sheet depending on the requirement. This is mostly done through automatic stitching machines for the highest quality.
I. Attach sweatband. With the visor attached, the sweatband is attached to the base of the crown followed by a decorative topstitch at the base of the cap. During this labels can be added to the sweatband.
J. Attach cloth snaps (button). The final stage is the addition of the cloth snaps at the top of the cap where all the panel seams converge.
K. Attach Closure. At the back of the cap attach an adjustable closure. This can be made of self-fabric or plastic closure.
L. Steaming the stitched cap. After stitching is complete, the caps are placed on a blocking machine that steams and fixes the shape of the cap. This ensures a greater life span of the caps as they are less likely to lose their shape after that.
We've partnered with Levi's C&A Walmart H&M OVS etc,and they gave us great ratings.
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.
Customer's satisfaction is our honor. We have not got any complaint from customer during operation. Moreover, we always work hard in order to finish products at the right time of event for customer. With skilful, professional and deveoted staff, we believe that we wil become one of the most prestigious cap production in guangzhou.