Manufacturer of Cotton Canvas Hats and Caps
Wholesale Canvas Sun Hat
Cotton Baseball P Caps Bulk
Denim Baseball Sun Cap Wholesale
100% Cotton Twill Bucket Hats Bulk
Cap & Hat Size and Fit Guide
Most caps and hats are designed around standard adult head circumference ranges, with adjustable closures extending the fit. The table below gives general size guidance in inches and centimeters.
Adult Cap & Hat Size Chart (Head Circumference)
| Size | Head Circumference (in) | Head Circumference (cm) | Typical Closure |
| S | 21.0 – 21.5 | 53 – 55 | Fitted or adjustable |
| M | 21.75 – 22.25 | 55 – 57 | Fitted or adjustable |
| L | 22.5 – 23.0 | 57 – 59 | Fitted or adjustable |
| XL | 23.25 – 23.75 | 59 – 60 | Adjustable (strap/buckle) |
| One Size / Adjustable | 21.0 – 24.0 | 53 – 61 | Snapback, strapback, velcro, or elastic |
To find your size, wrap a soft tape measure around your head about one inch (2.5 cm) above your ears and eyebrows — roughly where a cap would naturally sit — keeping the tape level all the way around. Snapback, strapback, velcro, and elastic closures extend a single manufactured size across a wider range of head circumferences, typically covering S through XL with one cap. Fitted caps are manufactured in specific sizes and do not adjust, so buyers ordering fitted styles need a fuller size breakdown across their order quantity.
Children’s caps are sized for smaller head circumferences, typically starting around 19–20 inches (48–51 cm), and most use adjustable closures to accommodate growth.
Fabric Options for Hats & Caps
The fabric you choose affects the look, structure, durability, and suitability for different branding methods. We manufacture caps and hats in three core fabrics.
Fabric Comparison for Hats & Caps
| Fabric | Weight & Feel | Best For | Branding Suitability |
| 100% Cotton Twill | Lightweight to mid-weight, soft, breathable | Everyday baseball caps, bucket hats, uniforms | Embroidery, screen printing |
| Cotton Canvas | Heavier, tightly woven, structured | Sun hats, heavy-use caps, outdoor gear | Embroidery, patches, printing |
| Denim | Heavy cotton twill weave, rugged texture | Fashion-forward and vintage-style caps | Embroidery, patches |
Cotton twill is the most widely used cap fabric — lightweight, breathable, and soft, with good shape retention. Canvas is heavier and more structured, making it ideal for sun hats and caps intended for heavy or outdoor use. Denim offers a distinctive rugged aesthetic suited to vintage-inspired or streetwear collections, though it is heavier and less breathable than standard cotton twill.
Customization & Branding options
All of our cap and hat styles can be customized with your branding. Here’s an overview of the methods available.
Embroidery
Embroidery is the most popular and durable branding method for caps, suitable for cotton, canvas, and denim. It works best for logos with a limited number of colors and clean lines, typically applied to the front panel, side, or back of the cap.
Screen Printing
Screen printing offers a flatter finish than embroidery and can reproduce more detailed or gradient designs cost-effectively at higher volumes. It works best on flatter fabric surfaces like cotton twill and canvas.
Woven & Sublimated Patches
Patches — woven, sublimated, or leather/faux-leather — offer a distinct textured look and are a popular option for multi-color logos or designs that wouldn’t translate well to embroidery.
Custom Labels, Tags & Packaging
Beyond the cap itself, branding can extend to woven or printed inner labels, hang tags, and custom packaging. See our packaging options for details.
Manufacturing Hats & Caps: What Buyers Should Know
Zephyrs Textile has manufactured hats and caps since 2002, supporting brands, retailers, and distributors with both standard bulk orders and fully custom private-label programs.
Bulk Production & MOQs
Bulk production runs are planned around a minimum order quantity (MOQ), which varies depending on fabric, style, number of colors, and branding method. As a manufacturer, we cannot produce or sell below our minimum order quantities — buyers planning smaller test runs should factor this into their sourcing timeline and budget.
OEM Manufacturing
OEM (Original Equipment Manufacturing) means producing caps to a brand’s existing specifications — fabric, style, sizing, and branding details are all defined by the brand, and we execute production to that specification. This is a common starting point for brands that already have a developed spec sheet.
Private Label Manufacturing
Private label manufacturing goes a step further: we can help develop the product itself — style selection, fabric, fit, and sample iteration — which the brand then sells under its own label. This route suits brands that have a concept and target market in mind but don’t yet have a finalized spec sheet.
Custom Sizes, Colors & Fabrics
Beyond the four styles shown on this page, custom cap and hat styles, fabric weights, and color ranges can be developed for bulk and private-label orders, subject to our minimum order quantities.
International Export & Compliance
As an exporter, production is prepared for international shipping with attention to labeling, packaging, and documentation requirements. Buyers should communicate any specific compliance or testing requirements for their target country early in the development process.
Frequently Asked Questions
1. What is the standard head size for an adult cap?
Most adult caps are designed to fit a head circumference of roughly 21.5 to 23.5 inches (55 to 60 cm), with adjustable closures extending the usable range by an inch or two in either direction.
2. What fabric is best for a sun hat?
Cotton canvas is a popular choice because it is durable, holds its shape well for structured brims, and provides good sun protection while remaining breathable for warm-weather wear.
3. Can I get my logo embroidered on caps?
Yes, embroidery is one of the most common and durable branding methods for caps, suitable for cotton, canvas, and denim, typically applied to the front panel, side, or back.
4. What is the minimum order quantity (MOQ) for custom caps?
MOQs depend on fabric, embroidery or print complexity, number of colors, and number of styles. Contact us directly with your specifications for an accurate MOQ.
5. What is OEM manufacturing for hats and caps?
OEM means producing caps to a brand’s existing specifications — fabric, style, sizing, and branding details are defined by the brand, and the factory executes production to that specification.
6. What is private label cap manufacturing?
Private label manufacturing involves the factory helping develop the product itself — including style selection, fabric, fit, and sample iteration — which the brand then sells under its own label.
7. How do I choose between cotton, canvas, and denim?
Cotton twill is lightweight, breathable, and versatile for everyday caps; canvas offers more structure and durability for sun hats; and denim suits fashion-forward or vintage-style collections.
8. What information should I provide to get a quote?
Provide the cap style, fabric and color preferences, branding method and logo files, quantity per style and color, and any specific sizing or packaging requirements.