Hat Trouble

[TOTWGraphics]

Has anyone had any trouble with EConcious brand hats?
We are trying to applique a piece of fabric onto them and having nothing but trouble- The hats have a heavy buckram backing to them and we are having constant needle breaks- Two different machines, different types of needles
Always at the same place in the design
We've sewn this on literally thousands of other hats from SanMar

Any help or advice is appreciated

Thanks!

[Chris & Cindy]

Either the stitch is to short or the density is to low for the cap in that area. What sews well on one hat may not on another brand. You are going to have to change to stitch file and/or machine settings for the different cap. There has to be a difference based on what you are saying. Are you using a ball point or sharp? 40wt or 60wt? If you tell me more I may can help you but I'm not familiar with the caps so I can't say much more.