A recent Verizon Fios video explores and examines Newark, New Jersey’s Unionwear, a manufacturer of scarves, hats, backpacks, and much, much more. The video opens with an interview with Unionwear CEO and President, Mitch Cahn, regarding the company’s background.
Mr. Cahn explains, “Unionwear is the manufacturer of baseball caps, military hats, sewn hats, backpacks, duffel bags—any sort of sewn accessory that can be made from woven fabric. By saying that these products are union made, it’s a type of shorthand for the fact that our products are made by happy, content, productive workers.”
When asked how they price their products competitively, the CEO says that one way of making sure that their products are competitively priced “is through the use of Lean manufacturing. Just because wages are higher doesn’t mean that labor costs necessarily need to be higher.”
Next, Mr. Cahn and the interviewer take a look at the factory itself. The camera pans over a section of the manufacturing facility as the company president explains that they are looking at roughly 1000 baseball caps before they are actually constructed. He runs through aspects of the production, such as fabric, a hydraulic clicker press that cuts the fabric for the hats into triangles, and other sections containing various parts of the soon-to-be baseball caps.
As he holds a completed baseball cap in his hands, Mr. Cahn runs his fingers along the various parts, demonstrating how each piece fits into the finished product. He offers up a little tidbit of information: every baseball cap has no less than 23 parts.
Moving to a different section of the factory, the video now focuses on workers at their various stations. This is where the tail end of the cap manufacturing process takes place, the sewing being done by hand and sewing machine. All the pieces come together here. Next will be the embroidery.
Depending on the cap, some parts receive embroidery while others do not. To achieve the best quality, the embroidery is done on cut parts of the hat before it is completely assembled. Because the embroidery is done on a flat panel instead of a curved finished cap, the artwork’s registration is improved, the imprint area is larger, productivity is improved, and expenses are lower. Workers now must finish the crown, attach the visor, and complete the baseball cap.
As the company president and the interviewer move to the section of the facility where the “baseball cap is virtually born,” the camera pans widely across the facility. It shows numerous stations and workers as various stages of the assembly process are being completed.
Mr. Cahn describes this final stage: “We’ve made the crown of the baseball cap, the embroidery has been added, we’ve made the brim, and now the crown and the brim will be attached together, and the label and sweatband will be added. Everything, once sewn together, is steamed, bagged, and boxed.” And voilà, you have a baseball cap, ready for distribution.
This video gives an impressive view of a baseball cap’s creation—from its infancy to the completed, final product. Not to mention all of the people who participate in the process. Knowing that these products, each and every one, are all put together with the bare hands of union employees is one of the major factors that sets this company apart from all the rest. These products are made in the USA, by hand.
Unionwear—American-made, America proud.
ABC News takes a deep dive into Newark, NJ-based Unionwear, a union shop producing all those Hillary, Bernie, and Anti-Trump logo products.
Josh: What’s up guys? I’m sure you’ve seen this before. We all have. This hat is actually currently made in downtown Los Angeles, but ground zero for campaign merchandise here in Newark, New Jersey at Unionwear. It’s not just Donald Trump’s campaign who has hired advertising companies. It’s Hillary, it’s Bernie Sanders, it’s Jeb Bush, it’s Mick Huckabee. Take a look at this table guys. There is New Jersey’s own Chris Christie. So these campaigns, they hire advertising firms that then use this company, Unionwear, to make all of these hats. Even some candidates who are no longer in the race. There’s Jeb Bush for 2016. So we’re seeing a little bit of it all. There’s also handbags here. I want to take you back there. Another funny thing, this place has been involved since Al Gore run. Ever since 1992, they have been making merchandise like hats and bags for the conventions. These employees are all engaged as well. I want to bring in the president, Mitch Cahn. Mitch, hop on in right now, live on ABC Digital. Talk about how your business has been impacted by the 2016 election?
Mitch Cahn: We’ve had to make more hats than ever. There have been so many candidates this year. We probably made baseball hats for nearly every candidate in the race. We’ll be doing work for the conventions. We’ll be doing work for parties in all 50 states.
Josh: What is it about your business, Unionwear here in Newark that it is so appealing, connected to these presidential campaigns on both sides?
Mitch Cahn: Well, for one thing, every single product we make is made in the USA. Every product is also union made as unions are a very big voting bloc in the election. We’ve made a name for ourselves by making presidential merchandise over the last 25 years.
Josh: Why don’t you show us some of those hats? Want to bring that Hillary hat?
Mitch Cahn: Sure. Here is a Hillary hat that we’re making. We are also presently making hats for Bernie Sanders and making hats – we’ve made hats for Jeb Bush and Scott Walker and Chris Christie during this election cycle.
Josh: Got it. Ben and Amna, while I have Mitch here and we’re standing here in Unionwear, you guys have any questions for us before we take you on a little tour and show you how these hats are made and introduce you to some of the employees as well?
Ben: Yeah. It’s actually funny because when like a team loses the Super Bowl, I always wonder where their hats go because they all of sudden bring out the winner hats. Oh, you won the Super Bowl. It says winner. What is the most obscure hat that he has? Like is there a hat from like 15 years ago that a candidate ran, and he just keeps the hat because it’s got to be very cool nostalgia.
Josh: Yeah Mitch as we know, not every candidate is successful. You’ve been in the business for a while. What is the most rare hat that you have? Have you kept any of them as collectors items?
Mitch Cahn: I keep some fun ones. I have a Kucinich hat. I have hats from John Edwards. I have hats from Joe Lieberman. I’ve got a lot of hats from senate candidates as well that are in our showroom.
Josh: While Mitch is talking and definitely chiming in with another question, got to love this Scott Walker army hunting hat.
Amna: Oh, look at that.
Ben: Wow, that’s duck hunting right there.
Josh: I will not put it on for you guys.
Amna: Josh, why don’t you take us on a little tour of the facility? Let’s see where these things are made.
Josh: Definitely. Mitch, let’s do a little tour. Why don’t we start with the Drumpf hats and what’s being made at this station right here?
Mitch Cahn: Sure. We start over here where we cut fabric into little triangles. In this area right here, we take the triangles, we call them panels and we sew them together to make the crown of the baseball hat. You can see the back of a baseball cap right there. This will end up being a Trump parody hat. It’s kind of a parody hat of the ‘Make America Great Again’ hat. Once the fronts and the backs of the hats are completed, we take them over to our embroidery area.
Ben: Josh, when you have a moment, can you ask him who orders these Trump parody hats.
Mitch Cahn: This is where we take the front of the hat and we do this before the hat is made. We’ll sew down a logo on the hat. So Melba, tell us exactly what you’re doing at this stage?
Melba: We’re running a sample of the Bernie Sanders logo.
Josh: Do you mind if I hold that real quick?
Melba: Yeah, sure.
Josh: So guys, the pattern goes on this USB, which goes inside this machine. Melba here at the embroidery station, she makes those. Mitch, we had a follow-up question on those Trump hats. Actually funny story guys. I’m not sure if you’re fans of John Oliver’s show, but John Oliver is kind of the reason why those hats are doing so well. Tell us about those Make Donald Drumpf. Hats?
Ben: Make Donald Drumpf again.
Mitch Cahn: Yeah. John Oliver is selling a hat on hbo.com that says ‘Make Donald Drumpf again’, which is a parody of the ‘Make America Great again’ hat.
Josh: Drumpf is of course—
Mitch Cahn: The family name of Trump. Apparently, it’s an extremely popular baseball cap.
Josh: Tell us what popular means. How many have you sold? Why are you continuing having to make these hats?
Mitch Cahn: We are – well, HBO is selling the hat. We’re making all sorts of parody baseball caps here, including that hat. Maybe around 30,000-40,000 parody Trump hats just this month. Almost as much as some of the other candidates’ hats.
Josh: As we continue to tour, another kind of funny interesting thing. Of course, Unionwear, this is a union company, and many people would think that the Republican Party not always particularly fond of unions. They do make the hats made here, because this is a company that can get them out fast, and they specialize in this type of campaign gear. But for Republican candidates, they will not put the Unionwear label on the hats. So it will not say the word ‘union’ anywhere on those hats. For Democrats of course, they do say union made.
Mitch Cahn: I’m sure there’s one around here somewhere. We just got them out.
Ben: Josh, is any candidate off-limits or is it all fair game for the parody hats? Will he do any candidate?
Josh: Mitch, are any candidate off-limits or you will do any particular candidate or company that comes to you with business.
Mitch Cahn: Yeah, we will do work for all candidates unless it’s someone that I as the president/owner of the business completely disagree with their positions. I don’t want to help somebody get elected who I absolutely do not want to see be President of the United States.
Ben: Who is he voting for then?
Josh: So far, that has not happened in this campaign.
Mitch Cahn: No.
Ben: Ask him who he is voting for?
Josh: Do you mind telling us who you’re voting for?
Mitch Cahn: No, I’m not going to say who I’m voting for. But I appreciate all the candidates giving us work here and supporting domestic manufacturing. It’s very important.
Josh: While we still have you guys, why don’t we show them some of the handbags that you guys make. I know Ben has been in the market for, in particular, this Hillary handbag. I think you’ll like it, Ben.
Ben: Absolutely. I need this, a man bag — wow, this bag is huge. It’s got all kinds of secret compartments.
Josh: It is huge. Made in America right here in Newark, New Jersey.
Ben: I’d be worried to wear Make America Drumpf hat–
Mitch Cahn: We make tote bags, backpacks, garment bags, all sorts of luggage, handbags. Here’s some samples. Some of the tote bags we’re making for the Hillary Clinton campaign right here.
Josh: So Mitch, just walk us through the process. An advertising company reaches out to you and says we want a handbag or a tote bag to sell, wear and how – talk us through how that works.
Mitch Cahn: They usually come out here first and vet us to make sure that we are completely made in America, and we’re not going to embarrass them. Then they’ll send us designs. We’ll prototype the designs, sent it to them for approval. Then just start making the merchandise, it will end up on the website of the candidate. Probably end up in the convention centers and at official campaign events.
Amna: So I guess a question for Mitch is the merchandise any indication of how a candidate is doing. I notice he does both Hillary and Bernie hats. Does one outsell the other?
Josh: Mitch, a question from our anchor, Amna in New York. What’s doing better, the Bernie merchandise or the Hillary merchandise?
Mitch Cahn: It’s really hard to say. They are actually selling about equally.
Josh: What is equally? Can you give us any sort of ballpark?
Mitch Cahn: We will do several thousand dozen hats per month or so for each of the candidates.
Josh: Off of your question Amna, when a candidate’s campaign kind of starts to tank, of course, they’re going to put in less orders. So sometimes, this might be the first place here in Unionwear where they know. We in the media, we’re reporting on it, but they kind of know – they didn’t put in that order. Mitch, tell us about maybe a story from the past when that’s happened.
Mitch Cahn: I usually find out about a candidate leaving the race from the news, but it has been exciting. A few times I’ve known about the vice-presidential candidate before the convention. We had to sign confidentiality agreements. In a way that sports champions are crowned with baseball hats, they have merchandise ready for those vice presidential candidates.
Josh: Which candidate was that?
Mitch Cahn: I think that was when it was Lieberman.
Josh: Lieberman running with Al Gore. So talk about how that process went. Did the campaign call you and say –this is the design we want but do they have security here.
Mitch Cahn: Yeah, the ad agency. They didn’t have security here. They called at the last possible minute and said we’re going to need these for the convention. We’re going to tell you who it is at the last second. You have to sign this that you won’t tell anybody. I probably knew for about 15 seconds before the news already hit the internet.
Josh: So guys, when it comes to our Veep sweepstakes kind of guessing who the vice-presidential candidate is, now I know that my assignment will be living in a tent outside Unionwear in Newark, New Jersey waiting to see what orders they get.
Amna: I think that might be smart. Hey, one last question for Mitch, Josh. Can anyone place orders because I’m thinking if we want to try to get some hats made for maybe a Ben Aaron run in 2020.
Ben: Oh, you’re in trouble.
Amna: We may try to get those orders in now.
Ben: You don’t want to know my family name.
Josh: Yeah, Mitch, can you walk us through the process of – I know we’re not candidates. We’re not with the campaign, but can anyone order merchandise from you. How do they go about doing that? How does the visual of the logo and that come. Do they give it to you? How does that happen?
Mitch Cahn: Sure–we have tens of thousands of products on unionwear.com. You can select your products there and upload designs. Someone
will call you back with a price quote. It’s a relatively painless, quick process. During election season, it usually takes about three-four weeks for orders to be delivered.
Josh: Got to tell you guys, a lot of the rallies that I’ve been to, there are people outside those rallies especially Donald Trump rallies with tables of merchandise. That merchandise is actually made in China a lot of the times or overseas. They are, I guess you could say, counterfeit merchandise not made here, because the candidates made in America, such a big issue and important to them, they don’t want their gear made anywhere else. So if you see a table outside, most likely that’s not made in America. How will our viewers be able to find made in America campaign gear, Mitch?
Mitch Cahn: Usually just be going to the candidate’s websites. They all have web stores. The political parties also have web stores. Official web stores like demstore.com or gopshop.com where you can find the official merchandise.
Josh: Well, that’s the scene here in Unionwear at Unionwear, Newark, New Jersey. Back to you guys.
Ben: Josh, thank you so much. We appreciate it. We’ll be expecting a strange random hat to be delivered at some point to this desk. We really appreciate it, man. I’ll be in big trouble. Make Colonomos great again. My real name is Colonomos.
Amna: Is that it?
Ben: It will be a bad thing. It wouldn’t even fit on the hat.
Amna: That’s going to take the whole width of the hat.
Ben: Yeah, it will go all the way around the hat.
Newark, N.J. – Mitch Cahn (right), President of Unionwear, provides a tour of his Newark, N.J., ball cap manufacturing facility to Coast Guard Capt. Robert R. Mckenna, Commander of Community Services Command, Bernard Reiner, a Coast Guard Auxiliary congressional liaison officer, Rear Adm. Daniel R. May, Commander of Personal Service Center, Wednesday, Dec. 14, 2011. The Coast Guard presented Unionwear a Certificate of Appreciation for their outstanding efforts, providing on-time delivery of the Coast Guard’s new standard uniform ball cap.
Video: Unionwear in Newark provides ‘boonie caps’ for U.S. Military: About half of the production in Newark’s Unionwear facility is military-related – which keeps the uniforms that our servicemen wear truly “Made in America”. (Video by Sarah Portlock / The Star Ledger)