Hoping some of you who actually run caps every day can help me out here.
I run a sports apparel shop in Tennessee and we've been paying someone else $7 to $9 a hat to do our embroidery. Doing about 5,000 caps a year, almost all of it 3D puff with team logos. March is brutal, we push around 50 hats a day for three weeks straight and then it slows way down. Rest of the year is easy.
Found two options and I'm stuck.
First one is a used Bernina E16 for $8,000. From what I understand it's really a Melco underneath, 16 needles, has the Acti-Feed tension thing and a laser. It's a 2017 or 2018 and has 51 million stitches on it from a lady who ran an Etsy shop. She's including the Melco OS software, cap driver and frames, 19 Fast Frames, a Hoop Master and something like 145 spools of thread. Bernina dealer 30 minutes from me has serviced it.
Other option is a brand new BAI Mirror for $6,400. 15 needles, warranty, comes with everything. Only does 850 spm on caps though and the tension is manual.
Few things I'm trying to figure out:
Is 51 million stitches bad on a Melco or is that just normal and I need to budget for a service? What would that cost me?
How do these Melcos actually do on structured hats with foam? Not flat stuff, actual stiff caps.
Anybody running a BAI Mirror on hats? Is 850 spm going to hurt me or does it not matter since everyone runs puff slow anyway?
Whoever runs the machine won't be an experienced embroiderer. Does the automatic tension actually save you on puff or is that just marketing?
And honestly if puff on structured caps was your main thing, what machine would you buy? What actually makes or breaks it, the machine or the digitizing or something else nobody mentions?
Appreciate it.