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structured cap embroidery problems

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I do both heat press and embroidery in my shop. Have a toyota 9000 embroidery machine.  Trying to get a small hat order out.

Been having no problems on caps.  This is my first structured cap order and we have broken 30 needles and ruined 5 caps. (order

is for 12).  We are new in the business and taking what we can get.  We are already using the #90 denim needles.  What gives :thumbsup:

Any help would be appreciated.  I have tried embroidery forums but find they are not very active.  Thanx,  PT

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All machines can't run all caps. You will find which caps your machine "likes". With that said, could the cap you are sewing out have a plastic stave and the needle is hitting it? Was the design specifically digitized for caps? Eline is a good embroidery forum run by Helen Hart and Yahoo's SWF site is another good one that has members with other machines too.                       

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Tory,  thanx for the feedback.  I'll try the other links.  Weren't you the one that reccommended the

Duraban (spelling?) machine for caps.  Why would it be the best??    PT

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I've never heard of that embroidery machine before?? I did recommended Barudan before though. They are one of the best for caps, hold registration and consistent results. The problem is usually due to hooping and flagging. Sometimes if you put an extra layer of tearaway under the design it will help. Another problem is digitizing; trying to use a left chest design on a cap. A cap is a curved surface which will sew differently than a flat. Both of those emb forums are great for information. Also, if you can go to an ISS show they are wealth of info too.

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Hi this looks like a fun thread!

I have never heard of duraban - You mean Barudan ? -

I just took a look at the Toyota 9000 - It shouldn't have a problem running caps. I have a brother Bes 960 (old but still bold). On tough jobs I use DBK 11/75 sharp point needles (organ, Meistergram, doesn't really matter) just remember to remove them once your off the cap frame or you'll cut holes in your shirts. Like the previous poster said plastic (nylon) backing is tough on thread you'll get a lot of thread breaks , see if the customer will switch to a structured cap with a fabric backing, Otto cap, KC Caps , or broder bros have a good selection. If there is no other alternative then try using a different type of thread, Polyester is very strong and break resistant, but is duller than rayon. Also if you have any control over the embroidery file, try to reduce density and widen the the stitch run Be careful not to leave empty space in a fill segment. Email me if I can be of any help.

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Duh....  Yes I meant Barudan.  Thanx for all the advice.  Will implement them tomorrow.  It's for

my daughter.  PT

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Hi I got a situation: as you can see on my profile pictures I'm trying to embroider on a cap but the color goes off every time the needle change and you can see the color of the cap right through them, please some advice here. Any help will be appreciated; thanks in advance.

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