Product enhancements & Manufacturing with Purpose

Product enhancements & Manufacturing with Purpose

At Eco Ninjas, patient safety and sustainability are not just values. They are the foundation of every product, partnership and decision we make. 

In recent months, we have responded to user feedback with a series of product enhancements, each designed to make our range even more practical, inclusive and enduring for clinical settings.

Latest Product Innovations/improvements

1. Durable Badge Protection

   To extend the lifespan of our badges, we’ve introduced a protective vinyl coating. This added layer resists wear from writing and wiping, keeping badges looking sharp and professional for longer.
   

2. Intuitive Hat Sizing with Colour Coded Tags

   Our hats now feature colour coded sizing tags on the outside, making selection simple and familiar. Staff can choose the size they need by recognising the colour that matches their preferred fit, similar to scrub sizing. This system also streamlines sorting and organisation during central laundering.
   

3. Inclusive Hijab Collaboration

   We’ve proudly collaborated with Dr Ushna Javed, representative of the British Association on uniforms, to develop our healthcare hijab. It is now available to order and supports inclusive, practical uniform solutions.
   

4. One Size Fits All Orthopaedic Hood

   Working alongside Mr Andrew Stevenson, Orthopaedic Surgeon and Co-Chair of the Royal College of Surgeons, we’ve created a fully adjustable, one size fits all Orthopaedic Hood. This design is ready to order and tailored to the needs of surgical teams.

A Trusted NHS Partnership

Since March 2023, we partnered with Northumbria Healthcare’s Manufacturing and Innovation Hub to develop our unique range of personalised operating theatre hats for the UK.

This collaboration is not just about manufacturing. It is about combining Northumbria Healthcare NHS Foundation Trust's expertise with our vision to create reusable products that support patient safety and reduce environmental impact.

Our theatre hats are produced at Northumbria Healthcare’s state-of-the-art Manufacturing and Innovation Hub, run by Northumbria Healthcare Facilities Management.

This organisation is a wholly owned subsidiary of the Trust, focused on delivering better healthcare through better products. All profits are reinvested directly into patient care.

Co-designed. Precision Checked. Clinically Aligned.

What sets this partnership apart is the level of clinical insight and attention to detail built into every stage of production. Each item is co-designed and checked by quality control, allowing for real-time feedback that supports ongoing refinement and improvement.

Each press stud is inserted with the exact pressure specified by the press stud manufacturers, and every hat is individually inspected to meet our strict quality standards. Our products are built to meet frontline clinical needs while reflecting our environmental values.

Certified for Quality and Sustainability

The Hub operates to ISO 9001:2015 (Quality Management), 14001:2015 (Environmental Management) and 45001:2018 (Occupational Health and Safety) standards.

These certifications provide confidence that each theatre hat is made with precision, care and a commitment to best practice

Durability and Performance Testing

The badge and hat fastening system has been rigorously tested by TWI, one of the world’s foremost independent research and technology organisations. Known for its expertise in materials joining and engineering processes, TWI used a repeatable peel test to confirm that the system withstands a minimum of 400 separations and reattachments with no decline in performance or visible wear.

The fasteners remained dimensionally stable, and although maximum, minimum and average load readings varied across different hat combinations, this did not affect functionality. The materials, including the hat, badge and fasteners, retained their integrity and appearance throughout testing in a temperature-controlled laboratory.

This demonstrates that the fastening system is reliable for clinical use, offering repeated removal and reattachment without compromising safety, durability or visual quality. View Report

Bridging Insight and Innovation in Theatre Hat Design

Our clinical insight and firsthand experience with surgical misidentification, combined with IT expertise, thoughtful design and trusted manufacturing support, enables us to deliver high quality products and guide hospitals through every stage of implementation.

We believe that safety, quality and sustainability should work hand in hand. From fabric selection to frontline use, every Eco Ninjas theatre hat embodies this principle. All of our products are proudly made in the UK.