A handmade tradition

The Toquilla straw hat, despite the name Panama, has been a hat, appreciated by many people, and actors, it has always been woven in Ecuador, Montecristi, more than 400 years ago, a craft, made by skilled hands, Montecristense, back in the year 1916, there were several presidents around the world, among them “Theodore Roosevelt”, they gave him a hat, and from that moment on, it was known as a panama hat, the art of weaving toquilla straw hats. has passed from generation to generation, Panama hats are made of a straw, which comes from the palm leaf, cardulovica palmata, also known as straw toquilla, which grows in tropical climates, on the Ecuadorian coast, which They are located, behind the Montecristi hill, The collogos cook them, for a time of 8 to 10 minutes, to obtain the fibers, which are dried in the environment, then the best fibers are selected, to weave the finest hats in the world , They are made completely by hand, from their beginning to their final finish, this depending on the fineness, which each artisan will make, from 5 days to 8 months, the finest fibers are used, to obtain the best quality, in Montecristi Don Simón Espinal from the community, “Pile” is the best artisan, his hats cost hundreds of thousands of dollars.

planta de paja toquilla
1.- toquilla straw plant

The “Cardulovica Palmata” plant, also known as toquilla straw, grows in tropical climates, on the Ecuadorian coast, behind Montecristi hill, it measures between 2.5 and 4.5 meters high, has simple, large, entwined, grouped leaves that form a fan-shaped rosette, 70 cm long, green in color, its soft fibers are used to make toquilla straw hats

2.- SELECTION the cogollos

The best cogollos are selected to obtain the best fiber, which is taken home, each artisan prepares the fibers at home, prepares it to make different qualities, the artisan selects the best fibers, which will be appropriate To weave the finest hats, it can be a 13-grade grade or up to a 62-grade top grade.

3.- despicado and preparation for cooking

Expert hands and eyes scatter or extract the fibers of the straw shawl of each head, this material is classified to then go to the cooking stage.

cocinado de la paja toquilla
4.- cooked straw toquilla
In this stage of the process the straw is subjected to cooking for 7 to 10 minutes to remove all the greenish color.
secado la paja toquilla
5.- drying process

Once the cooking process is finished, the toquilla straw is placed to dry to the environment, since it is ready to start weaving.

6.- hand-knitted

To start the fabric 8 fibers are taken and then 8 more fibers are taken, making a total of 16 fibers until obtaining a template.

7.- montecristi hat template
This is the appearance of the hat template once it has been made.
8.- wooden mold

Once the template is ready, it is placed in a wooden mold to continue its elaboration, the time of elaboration depends on the fineness of the hat.

9.- hat cup fabric

To start the fabric 8 fibers are taken and then 8 more fibers are taken, making a total of 16 fibers to weave.

10.- auction of the montecristi hat
This is the appearance of the hat template once it has been made.
11.- asoque of the hat

Before attaching a thin hat you have to moisten the edges of the hat between 10 to 15 minutes this is so that the fiber is very soft and has a good finish, this work is about 30 minutes each hat, if it is a finer hat asoque will be about 2 hours.

12.- washing of the montecristi hat

This process is done with a normal soap that is white, it consists of removing the dirt from the hat and is done for about 5 minutes each hat.

13.- Uncrown of the montecristi hat

This consists of cutting all the straw that is on the inside of the hat so that there are no imperfections.

14.- Smoked from the hat

To burn the fine hats they have to be wet, so the sulfur penetrates the fibers and remains as white as possible.It is placed in an aluminum container with sulfur then it is lit with charcoal embers.

15.- drying of the montecristi hat

Then it is removed from the smokehouse oven to dry again so is ready for the next step, ironing the cup and the skirting of the hat.

16.- lying down from the montecristi hat

This procedure involves ironing the cup and skirt of the hat.

17.- beaten hat
The hat is beaten with a wooden masseter on a very smooth stone, 5 hats are sprinkled with sulfur for 30 minutes, this helps to soften the hat until it is very soft as silk. Then clean it with a cloth to remove the sulfur and iron it again.
Planchado del sombrero
18.- ironing of the montecristi hat

The cup and the skirt of the hat are ironed again so that it is soft and able to give it the shape of different styles.

19.- HEAT OF THE HAT
To give the design to a thin hat an aluminum mold is heated to high temperatures, the mold is chosen according to the size of the customer’s head.
20.- press
After warming up the hat, he takes it to a press for about 4 minutes until it is well ironed.
forma del sombrero
21.- molding of the montecristi hat

Montecristi hats are molded by hand, this requires a time of about 15 minutes for each design.

22.- PLACE ribbons

The inner tape or morocco is placed, this is to protect the sweat from the head. The outer tape is according to the client’s taste.

etiqueta
23.- labeled
Every fine hat that is sold in our store is marked with its respective MODESTO HATS label in order that our customers are sure that they buy an original hat 100% made in Montecristi.
24.- packed of the montecristi hat

All our fine hats are packed in a cardboard box, perfectly  protected from damages that could get during its transportation.