Pincroft Dyeing & Printing, Chorley - SME (Chemicals)

Pincroft Dyeing & Printing is celebrating after achieving cost savings of over £700,000 a year through a resource efficiency drive at its plant in Adlington, Chorley.

The specialist in the bleaching, dyeing and printing of workwear fabrics has worked with an ENWORKS adviser based at Groundwork Pennine Lancashire since 2007. More than 35 separate resource efficiency improvement projects have so far been identified.

The company’s annual savings have accrued to give total cost savings of over £1.3 million to date, and a further £1.2 million of identified annual savings are still in the pipeline.

The achieved annual savings also come with 18 tonnes of associated carbon dioxide equivalent (CO2e) savings, with opportunities identified to save a further 2,300 tonnes a year.

Successful initiatives

Examples of low-cost and no-cost improvements Pincroft has been able to make include:

  • £64,900 a year saved by improving the controls managing the flow of chemicals on the chemical impregnation line, to minimise waste.
  • £12,500 a year saved by re-circulating waste water from the fabric cooling units for re-use in the production process, to avoid it being discharged as effluent.
  • £2,000 a year saved by improving manual controls for the drying cylinders, to improve energy efficiency.

Following investigation work on-site, a caustic recovery plant was also installed to re-circulate caustic soda and water used in the site’s dyeing and printing processes. The system is saving an additional £240,200 a year, after a payback period of just over a year.

A further one-off investment of £15,000 was made to install facilities for collecting and storing surplus chemicals from the fabric treatment baths, for re-use in future dye runs. This has generated annual savings of £260,500.

'Valuable contracts'

Ian Rawcliffe, Pincroft’s technical manager commented: "Being able to show evidence of our environmental credentials has undoubtedly helped us to retain valuable contracts."

Work is now underway on a range of new projects on site, including insulating bare steam pipes to avoid heat loss, installing electricity and gas meters to monitor energy consumption, fitting automated control systems to optimise drying processes, and reducing the amount of water used for washing.

Case study published on 19 May 2011