Getting through the production process of braid hats with master craftsmen

Until the braid hat is born

The "braid" in "a braid hat" refers to a tape-like string made of various fibers such as Japanese paper, hemp, and polyester. The hat is made by sewing the string in a spiral pattern.

 

Generally, the braid tape used is 5 to 6 mm, leaving a margin of 1 mm to sew it up .

 

It is the handiwork of a skilled craftsman to sew this 1 mm seam margin uniformly without removing the stitches.

 

The Toh Koh Koga factory braid hats are carefully sewn using sewing techniques accumulated over the years, and can be used for a long time due to their solid sewing.

 

In addition, at the Toh Koh Koga factory, we pay close attention to the last finishing touches to create braid hats that will make a lasting impression on our customers.

 

 

 

 

1. Forming the tip of the hat

 

 

 

Sewing starts with making a round or oval whorl.

 

The round or oval whorl is a matter of personal preference, but it is also important to determine the size of the hat, as it is related to the shape of the crown.        

 

 

 

2. Sewing the crown  

 

 

 

To make the hat fit comfortably, in the process of sewing a craftsman manually verifies the size with a mold to carefully adjust it.

 

 

3. Attaching the brim

 

 

The slope and length of the brim are important factors that create the general mood of the hat.

 

Elegant, casual, cute... we create hats that appeal to our customers' tastes.

 

 

 

The angle of the brim is determined by the angle between the material and a sewing machine needle. Although the mold is used, the sewing process must be carried out by hand, as it is only by means of craftsmen handiwork the product is completed.

 

4. Making the tuck strap

 

 

 

The part of the hat that touches the forehead is called a tuck strap.       

 

It serves to adjust the size of the hat and to remove perspiration.                                                                                                                          In the Kanto region, it is generally called “suberi,” while in the Kansai region, it is called “binkawa”. In the Kansai region, it is called “binkawa”, because the hair on both sides of the face was referred to as “bin” in olden times, and the slipper was made of leather (“kawa” in Japanese)  in the past, hence the name “binkawa” appeared.

 

 

5. Finishing work

 

 

 

 

While inspecting the product, we check the seams for out-of-stitching and at the same time cut the threads that remain during sewing.                                                                                                                               

It requires a very high level of concentration, as we carefully check for stitching errors of 5 to 6 mm in width.

 

This insistence on never missing a stitch is also a tradition at the Koga factory. If a puncture is found...  we will, of course, repair it with care.

 

 

 

6. Verifying the shape with the mold

 

 

 

 

While applying heat, we carefully shape the crown and the brim.   

 

The temperature and time vary depending on the material of the hat body, the material of the slipper, and the shape of the hat, so if there are 100 different hats, there are 100 different finishing methods.                                                                                                                                After the craftsmen have carefully and meticulously completed finishing work by hand, the hats then are packed in bags or boxes and shipped to the customer's destination.

 

 

 

 

 

Hats are made by hand, not by machines.                                                                                                                   

We work hard every day at our factory to deliver the warmth and love of our hands through our hats.                                                                                                                              

Try our braid hats produced at Toh Koh Kago factory and see how comfortable they are!