From sketch to stitch: our cap production process.

Every production run starts with a stitch file. The buyer sends the logo (AI, EPS or high-resolution PNG) and the cap front size in millimetres. Our in-house digitizer rebuilds the artwork as a stitch map: each color becomes a thread change, each shape is broken into a sequence of satin, fill, running or bean stitches.

We email the stitch file back as a .DST or .EMB preview along with a thread-color reference (Madeira or Coats & Clark). The buyer approves, or asks for a revision - typically one to two rounds. Once locked, the file goes to the embroidery floor and stays there for the life of the SKU; re-orders do not re-digitize unless the logo changes.

What you send

• Vector logo (AI / EPS / SVG) - preferred
• Or high-resolution PNG with transparent background, at least 600 dpi at final cap-front size
• Logo width in millimetres (most caps take 70 to 95 mm wide on the front)
• Thread colors (PMS code, brand reference, or a swatch)

Front-panel embroidery is the heart of the order. The cut and shaped front panels are mounted on a tubular plastic frame, then loaded onto a multi-needle industrial embroidery head — typically a 12-color, 15-needle Tajima or Barudan. Each cap runs through a single hooping, with the thread colors auto-switched from the digitizer file.

Production speeds:

• Standard 4 to 7 thousand stitches (logo only): 90 to 120 seconds per cap
• Medium 10 to 15 thousand stitches (logo + small text): 2 to 3 minutes per cap
• Heavy 20+ thousand stitches (full-front art or dense fill): 4 to 6 minutes per cap

Backings are selected by the digitizer based on the stitch count: tear-away for under 10k stitches, cut-away for denser designs that need long-term stability. Thread is Madeira Polyneon 40-weight polyester (the industry standard for color-fastness and wash durability).

Quality gates during embroidery

• First cap off the line is checked against the approved sample before the run continues
• Every 50th cap is checked for thread breaks, registration drift and backing residue
• Any cap with a thread break or registration error is set aside for the rework station

QC happens three times for every production run.

1. Inline (during production): each operator self-checks every cap; the line lead re-checks 1 in 10 caps against the approved sample. Critical defects (wrong color, misaligned embroidery, broken stitches) stop the line.
2. Final (after production): AQL 2.5 inspection on a random sample — we pull 32 caps from a 1000-cap lot, 50 from a 3000-cap lot, and 80 from a 10,000-cap lot. Critical defects must be zero; major defects under 2.5 percent.
3. Pre-shipment: finished caps are folded, poly-bagged, packed into inner boxes (typically 25 caps per inner box), then master cartons (50 caps per master carton). Carton labels include style, color, size breakdown, batch number and the buyer's PO.

We send the buyer an inline QC photo set, a final inspection report, and a pre-shipment photo of the packed cartons before the goods leave the factory.

What is the difference between hand embroidery and machine embroidery?

Hand embroidery is stitched one stitch at a time by a needle operator. It is slower, more expensive, and shows visible irregularities on the back of the cap (small knots, slight uneven stitch length). Machine embroidery uses a computer-digitized file and a multi-needle industrial head, typically running 800 to 1200 stitches per minute with uniform stitch length on a tear-away backing.

DTC family caps from CZEVIP are hand-embroidered for the soft hand-feel; OEM bulk production is machine-embroidered for speed, repeatability and cost. See our guide on spotting hand embroidery for a deeper look at the difference.

What is the minimum order quantity for OEM embroidered caps?

MOQ starts at 100 caps per style per color. Mixed-size orders are allowed (for example, 60 medium + 40 large across two colors is fine). For a fully custom panel fabric, custom color dye or custom labels, MOQ rises to 300 to 500 per style. Sampling orders (5 to 20 caps) are accepted but priced at the per-cap prototype rate.

How long does an OEM cap order take?

Standard production lead time is 25 to 35 days after sample approval, plus 7 to 14 days for ocean freight or 3 to 5 days for air. Sampling (pre-production sample, counter-sample, and final PPS) takes an additional 10 to 15 days from artwork lock. Rush orders under 1000 caps can sometimes be expedited to 15 days; please email info@czevip.com to discuss.

Do you do custom logos?

Yes. Send us the logo as a vector file (AI, EPS or SVG) or a high-resolution PNG (at least 600 dpi at final size). Our digitizer converts the artwork to a stitch file, which we email for your approval before production. The digitizing fee is $25 per logo and is waived on orders over 1000 caps.

Are your caps OEKO-TEX certified?

Our standard cotton twill is OEKO-TEX Standard 100 certified (Class II, direct skin contact). OEKO-TEX certificates and lab reports are available on request with each production batch. We can also source recycled cotton twill and GOTS-certified organic cotton for an additional material surcharge of about 12 to 18 percent.

Can I visit the factory?

Yes. Our partner production lines are in the Jiangsu and Guangdong regions of China, with sales and sampling support in Brooklyn, NY. We welcome buyer visits by appointment. For visits during peak production, please give us two weeks' notice so we can arrange floor access and translation support.

What file format do you need for logos?

Vector files are best: AI, EPS, CDR or SVG. High-resolution PNG (transparent background, at least 600 dpi at final cap-front size) also works. Please avoid screenshots, JPEGs from social media or files under 100 KB — they almost always need to be re-drawn, which adds cost and time.

Do you offer custom labels and packaging?

Yes. We do custom main labels (woven, printed or heat-transfer), care labels, hangtags, belly bands and inner box printing. Custom labels start at 1000 pieces per design. Packaging options include individual OPP bags, gift boxes with magnetic closure (like our Mom & Dad Set), and master cartons up to 50 caps per carton.