At the Huévar del Aljarafe factory of Inés Rosales, a single worker can shape up to 10,000 olive oil tortas by hand in one shift. Reaching that pace takes more than repetition: the work demands six months of intensive training and large manual dexterity. Information from Juan Carlos Espinosa, the company’s general director, training starts with a test of natural ability; candidates with the right touch and coordination are invited to continue.
Espinosa describes mastering the signature movement as a gradual process. Trainees work alongside experienced labradoras, learning the precise gesture for flattening each piece of dough. The aim is to build muscle memory until their hands work almost automatically, with less need for constant visual guidance. For many, progress stalls after a few months; only about 10% of those who start training reach the required speed and consistency.
Precision in Every Gesture
During production, workers use screens showing real-time images of tortas moving along the line. These visual checks help them spot differences in thickness: a torta that is too thin can caramelize and darken in the oven, while one that is too thick may stay pale and undercooked. Workers adjust their technique as needed, maintaining the required size and thickness while preserving the shape that defines the product.
Despite advances in automation, the final shaping of each Torta de Aceite Original remains a manual task. Machines divide the dough into equal portions; workers shape each piece by hand to achieve the traditional finish. Attempts to mechanize this step have not preserved the texture and flavor that distinguish the brand.
A Tradition Shaped by Women
All of the labradoras at Inés Rosales are women, a pattern Espinosa attributes to the company’s experience rather than a formal policy. The craft dates back to the company’s founding in 1910 by Inés Rosales Cabello and has passed through generations of women from Castilleja de la Cuesta. The company moved to its current location in 1991, while the core method remained unchanged. In 2013, the European Union registered “Tortas de Aceite de Castilleja de la Cuesta” as a Traditional Speciality Guaranteed; the registration identifies manual shaping and olive oil as defining elements of the product.
Each day, 16 labradoras per shift help produce around 300,000 tortas, with every piece passing through skilled hands before baking. The demanding training and consistency the role requires help explain why the craft depends on experienced workers.
Technology Meets Tradition
Inés Rosales pairs traditional handwork with modern quality controls. The production line uses a Hazard Analysis and Critical Control Points (HACCP) system for food safety and traceability. Screens give workers visual feedback to help them maintain production standards, while the shaping remains manual.
The balance between heritage and innovation reaches beyond food production. Integrating new technology into traditional industries can spark debate, as it did when France deployed the Airbus A400M firefighting kit while Spain awaited certification, a contrast between rapid adoption and the certification process. (Read how France’s rapid adoption of new firefighting technology contrasts with Spain’s approach.)
Protecting a Recognized Method
At Inés Rosales, six months of training safeguards a method recognized across Europe. The emphasis on manual skill ensures each torta meets the standards that have defined the brand for more than a century. In a sector where efficiency often takes priority, the craft demands practiced movement and precise work.
