We start with a high quality cotton webbing
Just like great food starts with great ingredients, we believe that our products should be constructed of the highest quality components. For the inside of our belts, we selected a high density cotton webbing that will feel substantial when tied around your waist. Expect to put some time into breaking in this belt - it isn't anything like the free belt you get when you sign up for your first class. :)
Measure twice and cut once
Our production crew are artisans in the truest sense of the word. I can't tell you how many times I've been yelled at by the frustrated production manager when my designs weren't specific down to the millimeter, failed to provide exact pantone colors to dye the fabric, or specify exact thread type used in the belts. I'm happy to say that with the guidance of the production manager's years of experience, we're producing a top of the line jiu jitsu belt that makes absolute no compromises in terms of quality materials and craftsmanship.
Cutting the hemp twill fabric
We start off with a strong 330gsm 100% hemp twill fabric. Hemp twill fabric becomes softer over time and ages gracefully. It comes on reams of fabric called "bolts" and is unrolled onto the cutting tables. The fabric is then stacked, pinned down, and cut by hand.
Stitching the belt
For strength, we opted to use a 40s/3 polyester sewing thread. This means that thread consists of 3 plies and that 1kg (2.2lb) of this type of thread will span 40km (~25 miles) when unravelled. In other words, it's pretty strong stuff.
Most production of the production staff have 15+ years of experience. Combine that experience with modern computerized sewing equipment, and you have yourself a meticulously put together belt.
Yes, we use a caliper to confirm belts are manufactured to specification. No, we do not mess around! :)