Shipping hats—from wide-brimmed sun hats to structured baseball caps—is not always straightforward. As part of the shipping process, every style needs specific care to arrive in pristine condition. Ensuring secure delivery requires proper packaging and shipping.
Whether you’re sending a single fedora or fulfilling orders in bulk for your flourishing hat brand, following these tried-and-true hatshipping strategies can help protect your products—regardless of shape, size, or material—and keep your customers happy.
Table of contents
How to package different types of hats
- Baseball hats
- Top hats and dress hats
- Cowboy hats and fedoras
- Wide-brim sun hats
- Beanies and winter hats
The art of hatpackaging is as diverse as the number of hat styles, with techniques varying to protect each distinct type. Here are packaging methods tailored for each shape:
Baseball hats
Baseball hats or caps, while seemingly simple, need specific attention to maintain their shape during shipping. Follow these guidelines for secure and form-maintaining packaging:
- Choose the right box size. Opt for cardboard boxes slightly larger than the cap’s circumference and depth. This leaves enough room for cushioning without creating unnecessary bulk and shipping costs. For retailers shipping in bulk, consider stackable, flat-rate boxes that can fit multiple caps and help reduce shipping costs while providing adequate protection.
- Preserve the hat’s shape. Gently fold the cap’s back inward to create a more compact form. Alternatively, stuff the crown with clean, acid-free tissue paper to maintain its structure.
- Protect the brim. Place a layer of bubble wrap or packing peanuts around the brim to shield it from potential crushing.
- Secure the box. Seal the box with strong packing tape, paying attention to any gaps.
Top hats and dress hats
The delicate materials and structured forms of top hats and dress hats require extra care. Here’s how to guarantee they arrive in tip-top shape:
- Upgrade the box. Reinforcement is key; use a strong cardboard box to guard against impacts. Consider a secondary box for added security if the hat is ornate or valuable.
- Support the crown and brim. Fill the crown and brim with clean, acid-free tissue paper, carefully shaping it to maintain the hat’s form. Use enough tissue paper to prevent movement within the box.
- Wrap the hat for protection. Gently wrap the entire hat in bubble wrap, securing it with tape to prevent shifting. Focus on the brim’s delicate edges.
- Position the hat properly. Place the hat upright in the box, ensuring it doesn’t touch the sides or top. Fill any remaining space with packing peanuts to prevent movement during transit.
- Secure the box. Seal the box tightly with strong packing tape and reinforce all corners and edges. Add “Fragile” and “This Side Up” stickers as an extra precaution.
Cowboy hats and fedoras
Cowboy hats and fedoras demand a balance between protecting their structure and maintaining their iconic shapes. Keep them in perfect condition with these tips:
- Choose a sturdy box. Choose sturdy boxes slightly larger than the hat’s diameter and crown height. Avoid flimsy cardboard that can’t handle the weight or maintain the shape.
- Stuff the hat. Gently stuff the crown with clean, acid-free tissue paper, molding it to preserve the hat’s form. Use enough paper to prevent movement and maintain structure.
- Wrap for security. Encase the entire hat in bubble wrap, securing it with tape to prevent shifting. Pay special attention to the brim’s edges and the creased crown of fedoras.
- Nestle the hat in place. Place the hat upright in the box, ensuring it doesn’t touch the sides or top. Fill any remaining space with packing peanuts to prevent movement.
- Seal the box tightly. Secure the box with strong packing tape, reinforcing all corners and edges. Add “Fragile” and “This Side Up” stickers to alert handlers about the item’s delicacy.
Wide-brim sun hats
Wide-brim sun hats offer sun protection, but their size requires special attention during shipping. Here’s how to ensure they arrive ready to shade in style:
- Box it big. Invest in rigid boxes. They must be larger than the hat’s diameter to accommodate the brim and taller than the crown’s height.
- Preserve the brim. Wrap the entire brim in bubble wrap, securing it with tape to prevent damage. Consider doubling the bubble wrap layer for extra protection.
- Support the crown. Stuff the crown with clean, acid-free tissue paper, shaping it to maintain the hat’s form.
- Lay the hat flat. Place the hat flat inside the box with the brim facing down to distribute pressure evenly and prevent crushing. Fill any remaining space with packing peanuts.
- Seal the box securely. Use strong packing tape to seal the box tightly, paying particular attention to corners and edges.
Beanies and winter hats
Because they’re soft and pliable, beanies and many winter hats usually don’t need boxing and padding for shipping. These packaging tips will help them arrive ready to ward off the cold:
- Use a poly mailer. Skip the box. Sturdy plastic mailers with secure closures usually suffice for individual beanies and offer a lightweight and cost-effective option.
- Double the protection. Before placing the beanie in the mailer, nestle it inside a clear, sealable plastic bag to keep out moisture and dirt.
- Put silica in the bag. Include a silica packet in each hat bag. This absorbs any moisture during transit.
- Protect the hat’s details. If your hats have delicate embellishments like pom-poms, fold them gently inward or protect them with tissue paper to prevent damage during transit.
- Take advantage of the flexibility. Because these hats are pliable, fold each beanie neatly and stack them flat to avoid deep creases or damage to embellishments during shipping.
Tips for shipping hats
- Consider the material of the hat
- Choose appropriate carriers
- Insure valuable shipments
- Provide return instructions
Consider the material, shipping carrier, insurance, and return policies to ensure a flawless shipping process. Here are tips for shipping hats:
Consider the material of the hat
Each type of hat, with its specific material and design, requires a thoughtful approach to packaging to ensure it still looks great after its journey.
For example, with straw hats, use proper packaging that supports the hat’s structure without compressing its natural fibers. For a rigid straw hat, create a custom-fit space within the box with soft padding that can absorb shocks. On the other hand, place wool hats in a breathable bag to prevent moisture accumulation, which can lead to misshaping. Ensure leather hats are wrapped in a material that prevents scratching and creasing.
Choose appropriate carriers
Choosing the right shipping company involves balancing service quality and shipping costs. Compare prices and prioritize reliability. Ground shipping is often sufficient for less delicate items like baseball hats, but consider expedited options for high-end or sensitive pieces.
Establish relationships with carriers to understand which shipping method best suits your hat types. Ensure hats are handled correctly during the shipping process. If you frequently send hats, you can try to negotiate volume-based discounts to reduce costs.
Insure valuable shipments
For high-value shipments, like designer or bespoke hats, shipping insurance is essential to protect against loss or damage. Document the hat’s condition before shipping and choose an insurance option that covers the total value of the hat. Understand the terms offered by the shipping company regarding insurance claims, and consider requiring a signature to verify delivery.
Provide return instructions
Not all hats are a perfect fit. Provide clear return instructions and include a pre-printed label with the package, making it easier for customers to send hats back if needed.
Including instructions for proper packaging for the return journey protects your business and the customer from incurring additional costs due to damage from improper packing.
How to ship hats FAQ
How do you ship a hat without ruining it?
To ship a hat without ruining it, use a box that accommodates its shape and size and add supportive padding to maintain its structure.
Can you ship a hat in an envelope?
Shipping a hat in an envelope is not recommended unless it’s a soft, unstructured hat like a beanie, which can tolerate more impact.
What size shipping box should you use for a hat?
The shipping box for a hat should be slightly larger than the hat itself, with enough room for protective packing materials.
How much does it cost to ship a hat?
The shipping cost of a hat varies by carrier, distance, and package size, generally ranging from $5 for a small, lightweight hat via ground shipping to $25 or more for expedited service or larger, decorative hats.