CDTI PID QUALI-FELT: Industrias Sombrereras Españolas
The objective of the QUALI-FELT project is to develop a new manufacturing process for hat-making products based on high-quality felts. The project starts from research into fixatives and resins with high biological content, which, together with the support of automated quality control, will help preserve the artisanal essence of the sector while making the manufacturing process more technical and sustainable.
The Problem
In a sector with a strong artisanal tradition, such as high-quality hat making, the main challenge is to modernise production processes without losing the essence, know-how and identity that make each product unique.
Industrias Sombrereras Españolas, S.A., a historic hat manufacturer under the Fernández y Roche brand, faces this challenge in a context marked by new demands for sustainability, efficiency and quality. The company, with more than 130 years of history, combines highly specialised manual processes with high-quality raw materials, which has allowed it to position itself in demanding international markets.
However, some key stages of the process, such as sizing and felt quality control, present important limitations. Manual visual inspection makes it difficult to detect subtle defects early, such as tone variations, shine or irregularities in resin penetration, which can affect the final finish of the hat.
In addition, the use of conventional fixatives and the generation of textile waste highlight the need to move towards more sustainable, efficient processes aligned with the principles of the circular economy.
The Project
To respond to this challenge, the QUALI-FELT project promotes the development of a new technology-enhanced and sustainable manufacturing process for hat-making products based on high-quality felts.
The solution combines research into new formulations of biobased fixatives and resins with the incorporation of artificial vision and artificial intelligence technologies to improve quality control in the production process.
Through these technologies, the project will make it possible to detect defects that are not visible to the naked eye, establish more objective inspection criteria and strengthen the traceability of pieces during manufacturing. All of this is designed as a support for artisanal work, not as a replacement, preserving the identity and distinctive value of the final product.
QUALI-FELT also incorporates a textile waste valorisation strategy, aimed at reducing waste and exploring new routes for reusing scraps and by-products generated during production.
The project, developed by Industrias Sombrereras Españolas with the technical support of AITEX, covers everything from research into materials and processes to the validation of a new, more efficient and sustainable production system prepared for future industrialisation.
The Impact
QUALI-FELT represents a significant step forward in the modernisation of artisanal hat making, showing that technological innovation can be integrated into traditional sectors without compromising their essence.
On the one hand, the project will improve production efficiency, reduce defects and optimise the use of materials. On the other hand, it will help reinforce the sustainability of the process through the development of biobased fixatives and the valorisation of textile waste.
Likewise, the incorporation of artificial vision and artificial intelligence will allow ISESA to move towards more precise, traceable and reproducible quality control, increasing the reliability of the final product and reducing dependence on exclusively manual checks.
This approach will strengthen the company’s competitiveness in high-end international markets, where quality, sustainability and transparency are increasingly relevant factors for clients and distributors.
In addition, QUALI-FELT opens the door to new innovation opportunities in artisanal manufacturing, positioning ISESA as a benchmark in the integration of tradition, technology and sustainability.
The Result
Thanks to the support obtained through CDTI PID, with approved funding of more than €240,000, QUALI-FELT is moving decisively towards the development of an innovative production process designed to improve the manufacturing of high-quality felt hats without giving up their artisanal character.
This financial support will be key to driving research into new biobased formulations, developing a quality control system based on artificial vision and artificial intelligence, validating the new process in real conditions and defining routes for textile waste valorisation.
In the long term, the project will allow Industrias Sombrereras Españolas to strengthen its position in premium markets, improve production efficiency and consolidate a value proposition based on the union of tradition, innovation and sustainability.
QUALI-FELT will also lay the foundations for new R&D lines, the future industrialisation of results and participation in strategic innovation programmes, strengthening ISESA’s role within the advanced and sustainable manufacturing ecosystem.
