A Week Inside the Berkam Studio — What Making Things Slowly Actually Looks Like
Most brand "behind the scenes" content feels like a performance. The perfectly lit workspace, the photogenic pile of ribbons, hands that never actually look like they’ve been working. We’ve all seen enough of it to recognize the formula.
This is something different: a reasonably honest account of what a week of small-batch production actually looks like, including the parts that aren’t especially picturesque.
Monday: Materials and Planning
The week begins with inventory. Not a romantic process — it’s a spreadsheet and counting what’s left on the ribbon spools. We typically work with about a dozen core fabrics: two or three weights of grosgrain in our main neutral palette, two silk weights, and whatever seasonal accent we’ve brought in.
Monday’s question is always the same: what do we have enough of to make a full run this week, and what needs ordering? Ribbon arrives from our French suppliers in relatively small quantities — we’re not buying by the kilometer. This is intentional, but it means planning ahead is essential.
By mid-morning we’ve settled on the week’s production: a run of low ponytail bows in grosgrain (black and ivory), and a smaller batch of French silk bows in the sage that’s been selling quickly. Plus a handful of custom orders, including one bride who wanted a specific ivory with a slightly wider center knot than our standard.
Tuesday: Cutting
Cutting day. Ribbon gets measured and cut to length before any tying begins, because consistent lengths are what give the finished bows their proportions. We use a cutting board and steel rule — about as low-tech as it sounds.
The less-romantic reality: cutting 40 pieces of ribbon at consistent lengths takes time, and it’s one of those tasks where your attention has to stay focused, or the variations add up.
We heat-seal the ends immediately after cutting. A ribbon burner — a small tool with a heated element — melts the cut edge just enough to prevent fraying. Silk requires a lighter touch than grosgrain; too much heat and you get discoloration at the edge.
Wednesday: Tying
The actual bow-tying begins. Each bow needs consistent loop size, knot tension, and trailing end length. When you’re tying twenty bows from the same ribbon, muscle memory helps, but your attention still has to stay on the work.
We check each bow against a reference piece before it moves to the next stage. Not because every bow needs to be mechanically identical, but because there’s a difference between natural variation and careless inconsistency.
Thursday: Hardware and Assembly
The bows get attached to their hardware — barrette clips, alligator clips, or left as free ribbon. We use brass fittings, which cost more than the silver-plated zinc alloy in most mass-market accessories. The difference isn’t just aesthetic: brass is denser, doesn’t snag fine hair, and ages in a way that looks intentional rather than worn.
Thursday also means photographing finished pieces. Natural light, a clean surface, minimal editing. We want the photos to show what the fabric actually looks like.
Friday: Quality Check and Packing
Everything gets laid out and inspected before anything enters stock. We’re looking for consistent loop size, clean edge sealing, secure center wrap, smooth-functioning hardware, and matching end lengths.
This is also when anything that doesn’t meet our standards gets set aside. It doesn’t happen often — maybe two or three pieces from a run of forty — but it happens, and those pieces don’t go out.
Custom orders get packed individually, with a card and care note. Nothing elaborate, but enough that opening the package feels like receiving something prepared specifically for you.
[See what came out of this week →]
Frequently Asked Questions
How are Berkam hair bows made?
Each bow is hand-assembled in small batches. Ribbon is measured, cut, and edge-sealed individually. Bows are hand-tied rather than machine-formed, then attached to brass hardware with a center wrap that covers the attachment point. Every bow gets checked against a reference piece before it enters stock or ships.
How long does it take to make a handmade hair bow?
From cutting ribbon to finishing hardware attachment, a single bow takes about 8–12 minutes depending on the style. In a batch of 30–40 bows, the time per piece decreases as the maker finds their rhythm — but individual quality checks mean you can’t rush the process without sacrificing consistency.
What makes small batch hair accessory production different from factory production?
In small-batch production, every piece gets individual inspection rather than statistical sampling. The maker checks knot tension, edge seal quality, loop symmetry, and hardware function on each bow — not one in twenty. It’s slower and more expensive per unit, but produces more consistent quality.
Why does Berkam use French ribbon?
French silk ribbon from the Lyon mills has a specific weight, weave density, and drape that creates better-behaved bows than synthetic alternatives or generic silk ribbon. It holds its shape, drapes naturally when tied, and avoids the plastic-like quality of cheaper ribbon.
How do you check quality in handmade hair bows?
Each bow gets compared against a reference piece from the same run. We also inspect edge seals for completeness, test hardware function, and check the center wrap’s position and tension. Pieces that don’t meet our standards get remade.
