Raw Materials
The main raw materials of hat and other headgears production plant are woolen fabrics, HDPE, fiber glass, etc.
The production process of hats and other head gears plant involves the following major manufacturing operations.
A-Production Process of Hat
- First, the hair tip is cut
from the rest of the wool- it’s not used in hat making. - The key to hat making is forming the cone and this is done in the forming machine.
- The fragile felt is then wrapped in cloth and placed between rollers for shrinking.
- Each machine can only reduce the size of the hats.
- The dying is carried out in large vats, each holding about 200 hats.
- Now the body is completed, the hats are tip-stretched and blocked.
- After the blocking and brimming, the hats come to the last of the wet processes-stoving
- The brim needs to be stretched flat so the body of the hat is pulled over a wooden black.
- After this, hast are automatically ironed.
- Pouncing is the first of the finishing process.
- One of the final processes is to place the hat in a frame to give the brim its ultimate shape called flanging.
- Finally, the hats are sanded once more, achieving the best possible finish on each hat produced.
B-Production process of Headgears:
- The appropriate shell mold for the model being produced is selected.
- High-density polyethylene pellets are pulled from a supply hopper by a vacuum system. Pellets of colorant are mixed with HDPE pellets in a ratio of 4% to 96%.
- The vacuum system then transfers the pellet mixture in to the injection molding press.
- With in the press, the pellets are heated to melt them. The molten plastic is injected into the mold to form the head gear. The press opens the mold and ejects the shell onto a conveyor belt.
- Picks the shell (head gear) up and cuts off the spruce (a lump formed where the molten plastic entered the mold).
- Component parts of the suspension system are produced. Injection molding machines form head bands, plastic “keys” that will be used to attach the suspension system to the shell, and nylon strips and gears for the ratchet mechanism that will head-banc size adjustment to fit the headgear user.
- Threads on end of a webbing strap through a slot in the end of a key. The worker folds the strap end back and sews it to the strap with a buttonhole machine, securing the key in a loop of the strap. The same process is repeated on the other end of the strap.
- Inserts both ends of the head-hand strip into the ratchet mechanism.
- Attaches a brow pad to the front of the head band strip by folding its tabs over the headband and hooking slots in the brow pad over nodules protruding from the bead-band.
- Attaches webbing strips to the head band by mating slots on the keys with nodules on the headband. On a six-point suspension system, only four keys are attached to the headband; the other two keys will attach only to the hardhat shell.
- Finally instruction booklet and the suspension assemble are placed inside the hat, and these components are placed into a plastic bag and box for dispatch.
Machinery and Equipment
- Blowing machin
- Dryer & sprayer
- Apron machine
- Iron
- Sewing machine
- Trimming Machine
- Moulds, Sand papers