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Manufacturing Process

Integrated Knit Beanie Production Process

At Nakato, our knit beanie manufacturing process is designed for consistency, efficiency, and stable export quality. From yarn inspection to final packing, each stage is managed under a structured and highly automated production system.

1. Yarn Inspection & Quality Control

All incoming yarn is carefully inspected for:

  • Color consistency (long-term shade stability)

  • Fiber composition

  • Tensile strength and quality standards

Maintaining consistent color performance across repeat orders over multiple years is one of our key strengths, ensuring reliable supply programs for global clients.

2. Knitting

Depending on product type, we operate:

  • Circular knitting machines (plain and cuffed knit beanies)

  • Flat knitting machines (cable knit and structured designs)

For circular knit hats, fabric is knitted in continuous tubular rolls and then cut into individual panels before inspection.

3. Cutting & Inline Inspection

After knitting, circular fabric is cut into individual panels according to required hat height.

Inline inspection is conducted immediately after cutting to identify:

  • Dropped stitches

  • Stitch defects

  • Panel dimension tolerance

  • Surface irregularities

Only approved panels proceed to the next stage.

4. Sewing & Structural Assembly

Panels are assembled through structured sewing processes, including:

  • Linking and joining

  • Dart sewing where required

  • Top closing for circular beanies

Following top closing, size and shape consistency are verified before proceeding further.

5. Decorative Processes (If Required)

For styles that include additional features such as:

  • Pom-pom attachment

  • Embroidery

  • Beading or decorative elements

These processes are completed prior to final finishing to ensure surface integrity and appearance quality.

6. Mending & Surface Finishing

After structural and decorative processes:

  • Minor imperfections are corrected

  • Loose threads are trimmed

  • Surface finishing is completed

7. Labeling & Restricted Area Control

After mending, products are transferred to a controlled labeling area.

At this stage:

  • Brand labels and hangtags are attached

  • Barcode stickers or required markings are applied

  • Compliance details are verified

This stage is managed under controlled access to ensure brand protection and accuracy.

8. Polybag Packing & Order Verification

Products are packed individually according to PO requirements.

Packing verification includes:

  • Style and color confirmation

  • Size assortment verification

  • PO compliance check

Inspection is conducted again before sealing.

9. Carton Packing & Final Inspection

Before shipment:

  • Cartons are packed as per buyer specification

  • Carton markings are verified

  • Random final inspection is conducted

Each shipment undergoes layered quality control before release.

10. Integrated Quality Assurance

Throughout the entire production flow, key stages are supported by automated systems to ensure consistency and process control.

In addition, trained quality control personnel perform independent verification at multiple checkpoints to ensure reliability, compliance, and export readiness.