How many hats do I need for my business?

Ordering branded hats sounds simple—until you’re staring at quantities and wondering if you’re about to overbuy… or come up short. Whether you’re outfitting your crew or handing hats out to customers, a little planning goes a long way.

For most businesses, the sweet spot is 3 hats per crew member per year.

Here’s why that number works:

If your crew wears hats daily—especially outdoors or in dusty, sweaty, or customer-facing environments—two hats often isn’t enough. Hats tend to break down faster than shirts, and worn-out headwear can make an otherwise professional crew look inconsistent.

For lighter use or office environments, 2 hats per person may be fine. For heavy outdoor work or high-visibility roles, 4 hats per person keeps everyone looking sharp year-round.

Pro tip: Always order 10–20% extra to cover new hires, turnover, or mid-year replacements. Small reorders usually cost more than planning ahead.

When hats are for customers, think differently. You’re not replacing wear—you’re creating impact.

A good rule:

One well-made hat that gets worn weekly is better advertising than 100 hats sitting in a drawer.

Plan intentionally. Match quantity to usage, build in a buffer, and prioritize consistency and quality. The right number of hats saves money—and keeps your brand looking professional all year.