Article: Why we make our hair towels in Portugal
Why we make our hair towels in Portugal
Before there was a hair towel, there was a search.
COTI didn't start with a hair towel. It started somewhere completely different.
The first attempt
I knew I wanted to make something textile before I knew what it would be. I found a small
manufacturer overseas and started developing accessory pillows, even though I wasn't completely sure that was the right product to start with.
Samples came. Nothing was wrong with them, exactly. They just weren't what I had pictured. The process was slow, the time zones made everything harder, and eventually I realized the bigger issue wasn't in the manufacturer. My heart wasn't in the product. So I stopped and put it down for a while.
The second attempt
When I came back to it, I changed the question. Instead of asking who could make my product, I asked where the best textiles come from. That led me to Portugal, a textile region where cotton and terry have been made for generations.
The call I thought was a waste of time
I found a mill I liked and asked for a meeting, mostly not expecting anything. They’ve been making textiles for decades. They’re large. Their minimum order quantities were far beyond anything I could afford starting out. I joined the Zoom assuming it wasn't going anywhere.
Near the end of the call, they told me they take on a small number of entrepreneurs each year. Not many, and only when they genuinely believe in the product and it's simple enough to fit what they do best.
When I came back to them with the idea for The Hair Towel, they were interested. I still don’t fully know why they said yes. But that conversation changed the direction of COTI.
What “simple enough” actually meant
The first sample came back close, just not perfect. The logo placement was off and a few construction details needed adjusting. The second sample was exactly what I wanted. Two rounds. That’s it.
We had conversations along the way, and there were details to work through on both sides. But I was working with people who knew how towels are made. They caught details before production that may have been missed otherwise.
That’s what you’re paying for when you make something in a place that knows textiles. Not just a country name on a label.
Why it matters for a hair towel
The Hair Towel is made in Portugal from knitted terry (80% cotton, 17% polyester, and 3% elastane) at 385 g/m². The knitted construction keeps the loops intact, while the elastane gives it just enough stretch to wrap securely and stay in place.
It’s a simple product. But simple products leave nowhere to hide. A hair towel is one fabric and one strap. Either it’s built well or it isn’t.
Questions people ask:
Where are quality hair towels made?
The best textiles tend to come from places that have been making them for generations. Portugal's textile region has produced woven and knitted goods for over a century, and its mills are known for high standards in cotton and terry. The Hair Towel is made there, at a mill that's been operating for decades.
Why are some hair towels more expensive than others?
It usually comes down to the fabric, the construction, and where it's made. Knitted cotton terry costs more to produce than thin synthetic microfiber, and the experienced mills often cost more than lower-cost manufacturing. With simple products like a hair towel, those differences become more noticeable over time.
What does knitted terry mean?
Knitted terry is a fabric where the loops are formed by knitting instead of cutting. That helps keep the loops intact, making the towel less likely to snag, pill, or wear out over time.
How many samples does a product take?
Every product is different. Working with an experienced mill helps catch details early, before production instead of after.
Is Portugal known for textiles?
Yes. Portugal has been producing cotton and terry textiles for generations. Many of its mills specialize in premium towels and knitted fabrics, which is one of the reasons brands from around the world manufacture there.
