James Dewhurst Ltd, Accrington (Manufacturing / Textiles)

Textile manufacturer, James Dewhurst Ltd, has made cost savings of £856,300 and carbon dioxide equivalent (CO2e) savings of 6,800 tonnes to date, thanks to ENWORKS.

The Altham-based business was founded as a weaving company in the early 1930s by entrepreneur, James Dewhurst. Today it manufactures high-performance textiles for use in product reinforcement and stabilisation, with an additional manufacturing site in the USA.

James Dewhurst has been supported by ENWORKS advisers atGroundwork Pennine Lancashire for five years, in which time 50 individual improvement actions have been identified.

Achieved savings

ENWORKS' recommendations have focused on the company’s use of energy, water and material resources. Altogether they will bring total annual cost savings of £476,300, which will continue to accrue, year after year.
 
Of the £476,300 of annual savings identified, £296,200 a year have already been achieved and have accrued to give savings of £856,300 to date. These come with achieved annual environmental savings of 309 tonnes of materials, 2,220 tonnes of carbon dioxide equivalent (CO2e), and 850 tonnes of waste diverted from landfill.

Examples of successful initiatives include a saving of £103,300 and 1,100 tonnes of CO2e a year by using existing equipment on site to rewind and reprocess residue yarn. This has resulted in reduced waste and significant money savings on the cost of raw materials.

A further £67,500 and 18 tonnes of CO2e a year has been saved by arranging for glues to be delivered in bulk, to reduce purchase costs and minimise the environmental impact associated with transportation.

A survey to find and repair leaks in the site’s compressed air system saved £27,100 a year in electricity costs, and the segregation, compacting, baling and recycling of different waste types also saved over £43,500 a year in waste charges.

In the pipeline

Meanwhile, £179,900 of annual resource efficiency savings are still in the pipeline at James Dewhurst.

These include opportunities to:

  • Replace old boilers with energy-efficient models
  • Minimise the use of shrink-wrap on finished products
  • Improve the way adhesives are used to reduce wastage
  • Recycle new waste types such as metal
  • Use preferred suppliers that offer returnable packaging, to minimise disposal costs.

Groundwork Pennine Lancashire is a member of the ENWORKS partnership, helping businesses in Lancashire and beyond to become more profitable and reduce their environmental impact by using resources more efficiently.

 

Case study published on 5 October 2011