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Hidrofer – Fábrica de Algodão Hidrófilo is celebrating its 50th anniversary this year, standing as a true European stronghold in its segment. Founded in 1975 by Carlos Silva, the company occupies a unique position in the industry: it is the only remaining cotton wool manufacturer in the Iberian Peninsula and the only one in Europe with in-house cotton bleaching capacity — a highly regulated and demanding process that has disappeared elsewhere in the continent due to high costs, strict environmental legislation and unfair international competition.
Half a century after starting out with just two employees, Hidrofer has become a global reference, mastering the entire cotton value chain. Every processed fiber goes through a closed-loop system of absolute traceability, combining technological precision with rigorous quality control. Its products serve the medical, cosmetic and personal care sectors, offering agility, high performance and reliability in highly demanding markets.
“Our agility and ability to adapt allow us to grow side by side with our clients, anticipating needs, optimizing processes and raising industry standards,” said Hélder Silva, current head of the company, in an interview with T Jornal.
Growth through differentiation and quality
In a global market where price often dictates survival, Hidrofer stands firm by focusing on quality, service and innovation. According to Silva, “in such a mature product, it is difficult to create added value,” which is why the company is pushing forward with innovation and patent registrations. Artificial intelligence is already integrated into several production stages, particularly in the detection and removal of impurities, metal particles and other potential contaminants — ensuring the purity and safety of its cotton wool.
The company is entering a new phase of development with the acquisition of new facilities in Avidos, Lagoa. This larger site will allow Hidrofer to consolidate all operations and expand production lines. “Cotton needs a lot of space — even finished products take up a huge volume,” Silva noted.
Sustainability: from cotton to energy
Hidrofer has been steadily investing in its green transition. It has an installed solar power capacity of 598.65 kWp, generating around 660,390 kWh annually and saving nearly 300 tons of CO₂ emissions per year. Water reuse systems are another cornerstone: currently, the company recovers 80% of the water used in hydroentanglement and 40% in dyeing processes.
This not only enhances environmental sustainability but also reduces operational costs by lowering dependency on municipal water treatment systems. Other circular economy measures include reusing water heat to supply other circuits, converting cotton sludge into natural fertilizer components, and transforming waste into biomass briquettes to fuel factory boilers.
A demanding global market
With strong market positions in Europe and North Africa, Hidrofer has successfully expanded into Latin America, parts of Asia and, more recently, the Middle East — where four consecutive years of investment in trade shows in Dubai and the UAE are paying off with exponential growth.
Still, Asian competition with much lower cost structures remains a constant challenge. Silva is critical of Europe’s heavy regulatory burden: “We are heavily taxed. There is no market more demanding than Europe, with enormous bureaucracy.” Labor costs, global crises and geopolitical instability also require tight monitoring of every business variable. “Survival is only possible through efficiency,” he stressed.
People, mission and future
Despite technological advances and digitalization — particularly in packaging — Silva highlights the irreplaceable role of people. “The issue is not hiring, it’s retention. Commitment and a sense of mission are essential, because client emergencies always arise that need to be resolved.” Team culture and internal engagement remain central to the company’s success.
Hidrofer is also strengthening its presence in retail, where it already operates with its own brands. While still a small share of global turnover, new products and positioning strategies are in the pipeline for the coming months.
With a solid name in the market and a clear strategy of differentiation, innovation and sustainability, the outlook is positive. The company expects to close 2025 with double-digit growth and anticipates another strong year in 2026.
Five decades after its foundation, Hidrofer remains a symbol of industrial excellence and Europe’s last stronghold in cotton bleaching — a rare legacy that is increasingly valuable in a world demanding responsibility, quality and innovation.