Your questions answered on our reusable theatre hat trail at Musgrove Park Hospital

We have been blown away by the wonderful comments from colleagues and patients across the world from our recent Instagram video about our reusable theatre hats trial at Musgrove Park Hospital. We had hundreds of questions, which our supplier, Eco Ninja's has kindly answered below.

New updates on 24 Sep 2025 now added in bold.

FAQ’s for reusable Badge Hats

Q) Have you thought about colour coding the labels? The yellow badges look bright.

A) We have listened to all feedback and now implemented four colours of badges.  Somerset Foundation Trust felt the yellow colour was too bright so they have all changed to blue, which blends in more with the hat & still stands out enough as a colour contrast to read the white writing on the blue background. These have been more accepted compared to the yellow by staff. We still offer yellow badges along with royal blue, white and red. Colour coding of job roles can now be done as well. 

Yellow badges with black writing have been identified the best colour contrast for everyone to read easily, including people with dyslexia and dementia- this is why this colour was selected for the ‘hello my name is’ badges for the initial trial.

Q) Embroidered and printed hats have been out there for some time, helping to improve communication. Why not use those instead?

A) We also sell embroidered hats, but ordering is complex and size specific to each individual. Embroidered hats cannot be centrally laundered due to the logistical challenge of getting all of the exact hats back to the right people. Somerset decided to centrally launder their hats, so the detachable badges work well to enable this to be done. Other challenges of embroidered hats are when staff leave, the hats leave with them as no one else can wear them whereas the badges can be simply attached to the correct size of hat and interchangeably worn, just like scrubs.

Q) Blank badges would be a good idea, that can be written on for people who visit theatre but aren’t a regular member of the team such as medical students or foundation doctors.

A) We do have blank badges and with role only so names can be added, as well as names & roles on the blank badges. Somerset have evaluated this, and the written-on badges have been successfully worn by Radiographers, Students, Registrars, Reps and Clinical Scientists. We have recently upgraded our writable badges with a vinal covering to make them last for longer.

Q) Pretty sure this is well established in new Zealand/Australia

A) Embroidered and printed hats have been used in Australia and New Zealand for a few years now, but the detachable badge hats are the first of their kind and Somerset is the first hospital that they have been used in worldwide. The issues and complexities of embroidered hats is outlined in the Q/A above.

Q) How are the hats being washed and can the badges be cleaned also?

A) The hats are collected at the end of each day and laundered at the Yeovil site. The clean hats are delivered back several times per week. Centrally laundering the hats ensures that they are all being washed at the correct temperatures to ensure effective cleaning/decontamination. The badges are to be washed with soap and water at the end of each shift also.

Q) All staff should know each other’s names and should introduce themselves properly to patients.

A) Due to the complexity of the theatre environment and high turnover of staff as well as frequent visitors to the department such as Radiographers, reps, clinical scientists etc, not all staff will know who these people are or the roles they do. Another factor is the staff learning who often do short rotations such as medical students, student nurses, student ODP’s and Registrars- by the time their faces are recognised by other members of the team, they have moved onto another unit. The name badges on hats can identify everyone from students to Surgeons!

Q) Is there an inclusive range available for staff from other cultures and religions?

A) We have two sizes of hats for staff with hair braids & a hijab design.

Questions from colleagues

Q) Colour coding of hats to size like scrubs would be useful.

A) Eco Ninja's have now adapted the ninja tags which are sewn onto the outside of the hats. We have added coloured tips to the tags to correspond to the colour codes of scrubs. Yellow = small, Brown = medium, White = large, XL= Pink, turquoise = one size fits all (Eco Ninjas colour code). 

Q) The fabric feels hotter.

A) Disposable hats have long been the standard, typically being paper-thin at approximately 20 gsm (grams per square meter). The new fabric hats, however, are significantly thicker at 145 gsm, which is the recommended minimum fabric weight for healthcare. While staff may initially find them unfamiliar, it is anticipated that they will become accustomed to them over time.

Extensive research has been conducted on thinner fabrics and alternatives to 145 gsm poly cotton, resulting in a comprehensive report. This report indicates that 145 gsm poly cotton is the thinnest recommended fabric for healthcare due to its durability, longevity, and comfort. As the hats undergo more washes, their comfort is expected to increase as they become more worn in.

Q) The bandana feels too small.

A) Eco ninja's have added a larger size bandana to our range now which should feel more comfortable for people with larger heads. 

Q) The bandana ties feel too thick.

A) Eco ninja's have changed the thickness of the ties on all bandanas now which have been approved by the surgical teams.

Q) The hoods feel too hot and tight.

A) Eco Ninja's have designed a one size fits all hood now which is adjustable by different positioning of press studs on the side. This has been approved by the surgical team. 

Interested in more sustainability news? Read about how our own Somerset surgeon has invented a new eco-friendly way to collect urine samples which can now be procured by NHS organisations.