PANAMA HAT PRODUCTION PROCESS

– Botanical name: CARLUDOVICA PALMATA –

STRAW HARVEST

The toquilla straw is harvested monthly, ideally during the full moon to minimize stress on the plant. Only part of the stem is cut, allowing the plant to regrow. The straw is harvested before the leaves fully open, ensuring the best quality. While new plants are sometimes cultivated, this is not done regularly. Toquilla straw does not have a fixed lifespan; its longevity depends on factors such as water availability and disease, typically lasting 20 to 30 years.

INITIAL PROCESSING OF TOQUILLA STRAW

The raw toquilla straw is meticulously classified and opened by hand. Once prepared, the straw undergoes a boiling process, is dried, and then smoked with sulfur in a dedicated shed to ensure proper preservation.

WEAVING PROCESS

Artisans take the processed straw and begin weaving the hats. The straw is classified and split according to the style and quality of the hat being produced. The weaving process is highly intricate, requiring anywhere from 2 days to 8 months, depending on the quality, size, and complexity of the design.

BURNING STAMP APPLICATION

Each hat receives a burning stamp immediately upon purchase from the artisan. This stamp ensures traceability and certifies that the hat has undergone the correct processes. The hats often move between different artisans after purchase—for example, to specialists who treat the brim edges (Azocadores) or fix the hat’s shape (Composers).

BRIM EDGE TREATMENT PROCESS (AZOCADO)

Weavers typically leave the brim edge unfinished. Specialized artisans, known as “Azocadores”, handle the task of tightening, evening, and finishing the brim edge to perfection.

BLEACHING, SUN DRYING, AND DYEING PROCESS

Hats are classified according to order requirements and then processed for bleaching or dyeing. The drying is often done under the sun to achieve the desired quality.

COMPOSING PROCESS (COMPOSTURA)

During production, hats can lose their shape. “Maestros Compositores” work on restoring and enhancing the hat body. This process includes washing, applying glue, treating the brim edge, ironing, trimming excess straw, and massaging the hats to ensure they are soft yet durable.

HOOD FORMATION (CAMPANA)

Once composed, the hats are finished as a hat body or hood (known as campana), preparing them for final touches.

FINISHED HAT PROCESS

From the Hat body to the Finished hat, it is molded and trimmed to meet the specifications of each order. Decorative trimmings are applied to create the finished product.

EXPORT PROCESS

Once the hats are fully finished, they undergo a final inspection to ensure quality and compliance with client specifications. Seals and labels unique to each respective client are attached to the hats. They are then carefully packed in export-grade packaging to protect them during transportation. Special care is taken to arrange the hats to prevent deformation. Once packed, the shipments are labeled for traceability and documentation is completed for customs and export requirements. This ensures the hats reach their international destinations in perfect condition.

INNOVATION AND EXPERIENCE

At Exportadora K. Dorfzaun, we don’t just follow market trends—we embrace them as opportunities to push boundaries and redefine excellence. Our unwavering dedication to research and development fuels our passion for creating hats that stand out. From perfecting rigidity and enhancing color fastness to ensuring resilience against the harshest sunlight, every improvement we make is driven by our desire to exceed expectations. It’s this relentless pursuit of quality that allows us to offer our customers something truly special—features and craftsmanship they simply can’t find anywhere else.