Wardle Storeys, Earby - SME (Manufacturing)

Vinyl manufacturer, Wardle Storeys, has saved over £460,000 thanks to ENWORKS resource efficiency support at its factory in Earby, Lancashire.

The company has been supplying vinyl-coated artificial leathers to the global automotive industry for more than 50 years. It also supplies the marine, healthcare, childcare and transport sectors.

Wardle Storeys has been supported by ENWORKS funded advisers from Groundwork Pennine Lancashire and has so far made annual savings of £96,200 and over 780 tonnes of carbon dioxide equivalent (CO2e). These have so accrued to give cumulative savings of over £460,000 and 4,170 tonnes of CO2e.

Achieved savings

The company has implemented a number of ENWORKS recommendations, including fitting a valve to convert a heavy oil burner to a light oil burner, to save on fuel, and fitting a high-efficiency motor to the factory’s extraction system to reduce energy consumption.

Variable speed drive compressors have been fitted to production equipment, to help save on energy bills, and the company is also recycling and reprocessing waste materials such as polyester and cotton fabric, PVC rolls, surplus plastisol and plastics.

These cost savings this has generated come with annual environmental savings of 231,000 kWh of electricity, 50,000 litres of fuel oil, 160 tonnes of plastic, and 178 tonnes of waste being saved from landfill.

Fresh opportunities

A recent follow-up review by Groundwork Pennine Lancashire identified 12 new opportunities for improving resource efficiency, which could help to save almost £180,000 and 3,200 tonnes of CO2e a year.

The projects include replacing skylights on the factory roof, to reduce the need for electrical lighting during the daytime, and carrying out a second compressed air survey to identify leaks that could be repaired to save on gas bills.

Switching from kerosene fuel to natural gas, and improving boiler plant efficiency and insulation, would also save energy.

Additional opportunities include optimising the efficiency of water cooling pumps on site, adjusting heating settings to heat larger areas more effectively, replacing old lamps with more energy-efficient alternatives, and improving staff awareness about switching off lighting and equipment when not in use.

The company is also planning to recycling a wider range of materials, including storage pallets, office paper and ink cartridges.

Altogether, these could bring annual environmental savings of 456,000 litres of fuel oil, 550 m3 of mains water, 1,000 tonnes of paper, and 10 tonnes of waste diverted from landfill.

 

Case study published on 31 May 2012