European Designer, American style. John Callanan originally from Cork City Ireland, had the privilege of studying with one of America's legendary milliners, Anne Albrizio at The Fashion Institute NYC. He would like to also acknowledge his mentor Martin Izquierdo, who suggested that he study hat making and to Douglas Highsmith for supporting the brand for the past 24 years. Callanan hats are distributed by Dorfman Pacific Hat Company.
Boiled wool/felt yardage is created commercially by first weaving or knitting wool fibers resulting in a fabric of uniform thickness.
TUBULAR KNITTING MACHINE
UNDYED AND UNBOILED HATS
FLAT MACHINE FOR MAKING SCARFS
The material may either be dyed first or left natural, with or without design and embellishment. Then "boiled" and agitated in hot water and suds. Thus, shrinking the fabric without the use of chemicals. The result is tighter and more dense and will have shrunk from twenty to fifty percent. Wool that has been boiled/felted is thought to be warmer, more durable and windproof.
If you have ever accidentally shrunk a wool sweater in hot water you are witness to the process of boiled wool.
In strictly woven fabrics, as opposed to knits, there is a similar wool finishing process called fulling.
During the boiling process the material is dyed into the fashionable colors of the season.
The workers check got even quality and a final pressing before the hats are sent to the sewing department for the final finish and trimming.