Nantong Foremost Garments & Accessories Co., Ltd.
Nantong Foremost Garments & Accessories Co., Ltd.

Hat & Cap Manufacturer

Foremost Hat has been a high-quality hat manufacturing company since 1996. Based on 5 factories in Asia (Vietnam, Cambodia, and China) , we can manufacture all types of hats efficiently and at a reasonable cost, using the same hat factories of top brands like Calvin Klein and Patagonia. 


The minimum order quantity for fully custom hats is 300 pieces. The minimum order quantity for customized logo hats is 48 pieces.


Hat Manufacture at Foremost

  • We provide high-quality production of all categories of hats, including custom baseball caps, trucker hats, dad hats, snapback caps, bucket hats, straw hats, beanies, balaclavas, felt hats, etc.

  • Currently, monthly capable of producing 1,700,000 woven hats, 400,000 knitted hats, 200,000 straw hats, and felt hats. Now there are 1700 professional staff and 1000+ advanced equipment.

  • The factory has passed professional certifications, including BSCI, GOTS, GRS, ISO, RMS, RWS, etc.

  • From design to sample, manufacturing, warehousing, and shipping, we provide you with a one-stop service.

Factory Figures

5
Factories
25
Designers
2.3 Million
Hats per month
1000+
High-tech equipments
1,700
Skilled workers
5000+
Styles per year
Woven Hats
Knitted Beanies
Braid Straw Hats
Felt Hats

How to Manufacture Hats Step by Step

Design

We are benefiting from Foremost's full-category factory resources. The designer team has established an integrated standard product development process, from style designing, product documenting, and raw material selection to technology production, aiming to provide our customers with an integrated hat producing and decorating service.

01.
02.

Sample

Foremost’s sample center has 20 CAD engineers, over 40 skilled sample sewing masters, and all kinds of special sewing machines. Monthly capacity reaches over 2000 styles, including photo samples, sales samples, and marketing samples, dedicated to making ideas into reality. Once the fabric and trims are ready, the hat samples will be finished and sent within 5 days.


Cut out

We have 20+ SHIMA SEIKI automatic cutting machines, making cutting more efficient.

Sewing
Trimming

Custom Logo

To popularize your hats, we provide embroidery logos, patch logos, print, washing, etc.

Quality Inspection

We have 5 inspection procedures to eliminate all defects.

Package

We provide custom package service, including labels, tags, stickers, plastic packages, etc. Hats can be sold to consumers once they are delivered to you.

Yarn Selection

The yarn determines the appearance as well as the function of beanie hats. We offer our customers a choice of 100+ types of yarns from acrylic to recycled and cashmere. It's our one-stop solution from yarn selection to delivery of the finished beanie hats.

Programming in Knitting

The knitting production cycle begins with making patterns and developing programs for knitting machines. We use M1 Plus software from Stoll knitting machine producer for programming. Thus, we can create unique knitted patterns and complicated jacquard figures.

Knitting-Computerized Flat Knitting Machine

We use Stoll machines to knit parts of the final beanies. There are machines with 12th, 7th, and 3rd gauge needles at our factory. Stoll machines are known for producing high-quality knitted fabric, and reliable and fast operation, which allows us to produce both small and big batches quickly, with creating patterns of any complexity, structure, and size.


Knitting-Circular Knitting Machine

Circular knitting is a form of knitting that creates a seamless tube. Work in the round is begun by casting on stitches as for flat knitting but then joining the ends of that row of stitches to form a circle.


Sewing Knitted Fabric

We use linking machines to assemble Fully fashion articles, where the edges of the parts do not need overlocking. Assembling with linking machines is labor-consuming, but brings better quality.


Embroidery

We customize the embroidery logo at the specified position according to the TP. Generally, most logos will be customized on the cuffed of beanie hats.

Trimming

Trimming is the process of sewing in the hat lining, adding any additional decorations, or even washing for a unique appearance.

Inspection & Package

This stage is quality control and inspection of beanie hats. Here, all beanie hats are viewed as compared to the sample created by the designer, and any excess or loose wiring, lining, or braid is cut and removed to complete the hat.

Braiding

Both natural and artificial materials can be made into braids either by machine or by hand. The size of the braid made by the machine varies from 10mm-25mm. The smaller the size, the more difficult the crafts and the more delicate the final straw hats.


Forming Hats by Braid

Forming straw braid hats is so special that it is not just a question of creating a perfect seam between braids, but of forming the shape of a hat during the sewing process itself. That means the process requires an extremely good eye, sensitivity, experience, and practice. The narrower and more delicate the braid, to more difficult it is to work.


Soaking & Stiffening

Soak and add the stiffener to the straw braid cone for stiffening, making it a different feel of soft and hard, as well as further shaping different shapes of hats.


Shaping

For this stage, Aluminum blocks are widely used, which require that the hat be stretched over the block and then Ironed. We have kinds of blocks to satisfy various style shapes.


Trimming

Trimming is the process of sewing in the hat lining and adding any additional decorations, such as bows, extra fabric, or rhinestones. This is truly the area where the designer's vision plays out. Adding additional fabric to create bows or adding a rhinestone cluster is often the reason why our hats capture so much attention.

Inspection & Package

This stage is quality control and inspection of hats. Here, all straw braid hats are viewed as compared to the sample created by the designer, and any excess or loose wiring, lining, or braid is cut and removed to complete the hat.


Cleaning

The main raw material of the felt hats is natural wool and rabbit fur, these natural materials are mixed with debris and lanolin, therefore, remove them to get better felt quality.


Cone Forming

This stage is to "card" the wool using a machine that combs and pulls fibers into a fluffy mass, then this material is wound onto a wooden cone, the shape and size of the cone in addition to the amount and weight of wool used determines the size, quality and weight of the cone.


Felting

The felting process uses steam and pressure to bind the wool fibers together, then the felt is rolled to consolidate and continue the felting process, the last act is carried out by a bumping machine to finally consolidate the fibers in the wool.


Dying

When dyeing the felts, the hoods are left to soak in the dye for 90-300 minutes, depending on the weight of the felt.


Wet Operation (Shaping)

The crown of the hoods is stretched to a standard size and shape, it is then dried in an oven and the surface is finished to the requirement.

Final polishing & Capeline

The material of felt hoods is all to do with how the surface of the felt looks. The hoods' surface needs to be brushed, clipped, polished, and combed, depending on the desired finish. Then make the capeline for final shaping.


Soaking & Stiffening

Soak and add the stiffener to the felt hood for stiffening, making the felt hood different feel soft and hard, as well as further shaping different shapes of hats.


Shaping

For this stage, Aluminum blocks are widely used, which require that the hat be stretched over the block and then heated by gas or steam. This is more modern and quicker, compared with vintage wooden blocks. While we have kinds of blocks to satisfy your idea.


Trimming

Trimming is the process of sewing in the hat lining, adding any additional decorations, such as bows, extra fabric, or rhinestones, and cutting or folding the brim of hats, to obtain the corresponding brim style and width.


Inspection & Package

This stage is quality control and inspection of hats. Here, all felt hats are viewed as compared to the sample created by the designer, and any excess or lose wiring, lining, or braid is cut and removed to complete the hat.


Turnaround Time

Sampling 5-7 Days

Production 7 to 30 days

Delivery 3-30 Days

By sea/air/express


CONSULT YOUR HATS&CAPS EXPERTS
CONSULT YOUR HATS&CAPS EXPERTS

We help you customize and manufacture premium hats that are worthy of your brand on time, and on budget.

Email
Email
hat@4mostcaps.com
Phone
Phone
+86-513-85675888
ADDRESS
ADDRESS
Headquarters:  #490 Yonghe Road, Nantong City, Jiangsu Province, China, 226000
ADDRESS
ADDRESS
Suboffice: Cincinnati, Ohio, US
ADDRESS
ADDRESS
Factory: Phum Boeng Thom2, Sangkat Boeng Thum, Khan Pou Sen Chey, Phnom Penh, Kingdom of Cambodia, Thanh Hoa, Vietnam
ADDRESS
ADDRESS
Do Trung Hamlet, Cam Tan Commune, Cam Thuy District, Thanh Hoa Province, Vietnam.
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