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Head-Ache

Cap America’s i3038 poly/cotton Mesh Back Cap is a medium profile six-panel structured cap with a modified flat visor.
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Even as it remains a key part of every uniform, team headwear has certainly not escaped the dual challenges of COVID cancellations and supply chain disruptions for the past year. Yet team dealers and their primary headwear suppliers have managed to keep ahead of the game with creative sales strategies, investments in distribution and on-trend new looks.

So even as teams return to the playing fields and hopes of full spring seasons return, it is those nagging supply chain issues that are dominating conversations in the team headwear business.

“The supply chain shortages have impacted caps as much or more than any item we typically order,” says Dan Cordi, owner of Zappia Athletics, Vestal, NY. “Customers are traditionally particular about specific hat vendors and styles, but they have become more flexible out of necessity,” he adds, pointing out that core styles from most vendors have been back ordered the majority of the year.

Filling the Demand

Back orders have caused teams to compromise in terms of style and preference when it comes to caps, but for some the issue extends beyond sacrificing their desired hat for the season. Instead, it might mean scrambling to get their hands on whatever caps they can in time to play ball.

“A lot of teams are going to hit the field without proper headwear,” says Jeff Covington, owner of Sports Spectrum, Chattanooga, TN. His biggest concern this year is filling school orders for baseball caps.

In the south, baseball season begins a bit earlier than other areas of the U.S., with the first games scheduled as early as February. However, as back orders persisted into the new year Covington says none of his custom orders will ship prior to March 1, which means teams might have to resort to a Plan B or even a Plan C to get sufficient hats for their players.

“When a company doesn’t have it, you have to move to options B, C or D,” says Covington, who finds himself asking customers whether or not they are open to other colors more often than he would like to — especially when he’s met with hesitancy from coaches who have their hearts set on outfitting their teams with the original styles they requested.

“When it comes to headwear people are reluctant to change,” he says.

The situation is similar but not as dire in the Northeast, since baseball season begins a bit later in the year than the schools in Covington’s region.

“We haven’t started to see a high demand for what spring’s supply needs will be,” reports Andrew Nickerson, owner of Wight’s Sporting Goods in Holden, ME. “Some of the vendors seem to be improving, while others remain status quo.”

Figuring Style Trends

Because the supply chain issues leave everything up in the air in terms of predicting delivery and managing orders, it’s difficult to project what players will be wearing this spring. For some, it might be easier to pinpoint what the new hot items are, while others are just happy to get whatever hats they can find.

“Sublimation continues to gain popularity,” says Cordi, who has seen this as a rising trend for 2022. “It is now frequently being requested for online stores and team apparel, not just uniforms. Augusta, Founder, Champro and other vendors have restructured their websites to focus primarily on custom sublimation apparel and uniforms,”

Sublimation may become more common as teams still hope to fill custom orders, but they realize the likelihood of receiving those orders has gone down. This method of printing could likely become the new norm until suppliers are able to get back on schedule.

However, Nickerson and Covington aren’t relying on sublimation as a reliable method for filling custom orders just yet, as they are primarily focused on giving their customers a viable back-up plan that will get teams their hats on time without having to order stock from other locations, which will ultimately drive up cost for both the dealers and the customers. For them, this is more important than finding new trends.

“The alternatives are what’s actually available,” explains Nickerson, who stresses that if the teams insist on a specific style they’ll be fortunate if it’s available.

“People are getting used to waiting for their product,” he adds, noting that customers’ increased acceptance of product shortages is more noticeable this year.

Predicting 2022 Challenges

Since supply chain issues aren’t new in 2022, team dealers might be able to base their expectations on the previous year. Whether or not that is a good or bad thing varies from dealer to dealer.

“We were extremely fortunate to have the year we did in 2021,” says Cordi. “There was a lot of demand every season for both apparel and uniforms and the biggest challenge was navigating through the supply chain shortages. Based on our numbers in 2021 and preliminary quote requests, we expect a busy Spring 2022 season.”

Being able to predict a busy season could be an advantage to dealers such as Cordi who can do their best to get ahead of the supply chain and order early enough to account for delay times and back ordered stock. Others unfortunately can’t do much to get ahead of the suppliers.

“I foresee the spring to be challenging,” says Covington, who hopes that some of his orders will begin to arrive on time in order to minimize the amount of unhappy customers who have to resort to other options. “There could be another wave of inventory,” he says with high hopes.

Unlike Cordi, Nickerson’s experience in 2021 was a bit more challenging and it might be too difficult to base his expectations for this year on the last.

“Last year it seemed like the majority of the hats we ordered were not available,” he says. “The reality is that so much is unknown. All we can do is communicate with our customers the best we can.”

With that in mind, Nickerson feels that this year will be better than the last and is hopeful that suppliers will be able to fill orders more easily in 2022.

“I think 2022 will see improvements. I think it will be slow, but I’m optimistic that things will improve,” he says.


CAP VENDORS RESPOND

Grace Schettler, Director of Sales, Cap America

“We have taken several steps to continue to combat supply chain issues in 2022. First, we’ve maintained our fast turn-times once inventory does arrive. We are able to get product out of our doors quickly once we receive the containers. Secondly, customer service always has been, and will continue to be, in constant communication about what is available and will keep our customer up-to-date with inventory arrival times. As we know, this information can change daily.  “We provide inventory levels on our website without a log in and have recently implemented a spreadsheet that shows only in-stock items that is updated hourly. We don’t expect the supply chain issues to improve very much throughout 2022, but we are confident that we are doing everything we can to lessen the impact on our customers.”

The i8503 is a Flexfit Perforated Performance Cap that is a mid-profile structured on-field cap with a shapeable flat round visor.


Chad Kennedy, National Sales Manager, The Game

“We have accelerated the frequency of inventory review and purchases and are taking larger inventory positions on key styles. Whereas before we would do a deep dive into inventory and trends once a month and place orders at that time, today we are doing that on key team styles on a weekly basis. This has allowed us to spot trends earlier and is giving us deliveries on a more constant basis.”

GB999 is a Low Pro Perforated GameChanger with a lightweight performance fabric and perforation to enhance breathability.


Derek Jensen, VP–Sales, Richardson Sports

“We believe the disruption to our global supply chain will continue well into 2022 and as a result we will continue to use all means of transportation, including air freight, to improve our inventory position and lead times. Simplifying our order processes, providing improved visibility to order status, inventory levels and estimated delivery dates, remains our key focus.”  

The PTS50 is the evolution of Richardson’s micro-mesh fabric, built to complement matrix mesh fabric used in PTS Uniforms.


Mike Hiskey, Creative Director, Pukka

“Global supply chain and logistics networks continue to be impacted by the pandemic. Fortunately, our business model of fully custom, made-to-order products naturally facilitates the prepositioning of raw materials and production capacity, so we have been in a good position to navigate these challenges. We continue to make refinements to our supply chain based on the challenges we face. We have made adjustments to our raw material sourcing, shipping logistics, capacity and production planning. 

The Mid Crown features a Mid Profile Crown Shape, soft touch Trucker Mesh Side and an ergonomic shape.


Brad Reagan, Senior National Sales Manager, Outdoor Cap

“Honestly and transparency have been our priority for supply chain and stock issues. We are ordering stock as fast as possible and paying astronomical rates just to get on a container. That portion is hard to control, but what we can control is being an asset to our customers.”

The MLB-600 is a Proflex cap with perforats ed side panels for extra ventilation new for 2022.

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Mar 30, 2022

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