Business & Export · Cap Encyclopedia
Cap Packaging Options
Packaging is where a $6 FOB cap either lands on a retail shelf ready to sell or ends up in a returns pile. Four options cover 95% of programmes — here's the cost, the fit and the failure mode of each.
Polybag — the baseline
Every cap ships in a polybag. It's the minimum barrier against dust, moisture and abrasion inside the carton — never skip it.
- Material: LDPE, 40–60 micron. Clear standard, frosted for premium.
- Print: 1–2 colours flexo on the bag, or a printed care sticker on the outside.
- Safety warning: suffocation warning required for EU / US retail. "Keep away from children" in local language.
- Closure: self-seal adhesive strip. Never staple — punctures the cap.
- Sustainable option: compostable PLA or recycled LDPE with GRS certificate adds ~$0.03/unit.
Hangtag
The hangtag is where brand storytelling and legal compliance meet. Every retail cap needs one.
- Card stock: 300–400gsm coated card. Kraft/uncoated for craft/heritage positioning.
- Content required: brand mark, style number, size, colour, fibre composition (EU/US law), country of origin, barcode/EAN.
- Attachment: plastic tag-pin through the sweatband or the back closure. Never through a panel — leaves a hole.
- String tag: waxed cotton string or ribbon through a punched hole for premium positioning. Adds $0.03–0.05.
- Print finish: soft-touch lamination, spot UV, foil stamp or emboss for premium tiers.
Cap-shaper (crown insert)
A cap-shaper is a moulded plastic or paperboard form that holds the crown round during shipping and shelf display. Without one, structured caps arrive with the crown collapsed and the brim flat.
- Paperboard: 350gsm folded insert. Cheapest, disposable after purchase. $0.15–0.20.
- Vac-formed plastic: PET or PP shell that matches the cap crown. Reusable, premium retail feel. $0.25–0.35.
- Tissue stuffing: acid-free tissue paper filled into the crown. Softer feel, higher labour cost.
- When to skip: unstructured dad hats and beanies don't need shapers — soft crowns pack flat.
Gift box
Gift boxes turn a $6 FOB cap into a $50 retail experience. Reserve them for premium tiers, limited drops or DTC subscription boxes — the unit cost matters.
- Rigid box: chipboard core with printed wrap, magnetic-close lid. $1.20–2.50.
- Two-piece lid & base: classic hat-box format. $0.80–1.50.
- Kraft mailer: corrugated printed mailer, DTC-friendly. $0.40–0.80.
- Inner detailing: tissue wrap, thank-you card, care card, sticker sheet — each $0.05–0.15.
- MOQ implication: custom-printed boxes need 500–1000 unit tooling minimum. Stock boxes with sticker branding work at low volume.
Which combo for which channel
- Promo / uniform: polybag + care sticker only. No hangtag, no shaper.
- Mass retail: polybag + hangtag + paperboard shaper. Barcoded, care-labelled.
- Streetwear DTC: polybag + hangtag + shaper + kraft mailer. Insert card and sticker sheet in the mailer.
- Premium / limited drop: tissue wrap + rigid gift box + shaper + numbered card. No polybag inside the box (looks cheap).
Retail-ready packaging in one PO
We produce polybags, hangtags, cap-shapers and printed boxes in-house — packed and shipped with your caps under one invoice.
Request packaging samples