Atkinson Dyeing introduces eco-friendly upgrades

Atkinson Dyeing has recently introduced major upgrades to enhance sustainability and update its operations. A key part of this progress is a modern heat recovery system that captures 60°C wastewater and uses it to warm incoming cold water to 50°C. This process reduces the facility’s dependence on gas and significantly cuts carbon emissions. At full capacity, the system is expected to reduce gas costs by 20% and electricity use by 10%.

Improvements include a more efficient winding area with 3D fans for better air quality, a newly insulated roof, energy-saving LED lights, and larger windows to let in more natural light. The use of reusable cones has helped cut plastic waste, and custom-built yarn-stripping machines have enhanced production speed and control. Additionally, computer-controlled dyeing machines have been installed, helping reduce water use compared to older systems.

Water and chemical use have also been carefully managed. The facility uses water directly from the river to lessen dependence on mains supply, and all wastewater is treated offsite to prevent any discharge into the river. Safety barriers have been placed under chemical storage to contain possible spills. The site has also focused on recycling, ensuring that cardboard, plastic, and wood are reused or properly recycled wherever possible.

On the technology front, Atkinson Dyeing has adopted the OrgaTEXcloud system to improve production planning and make tracking across departments more efficient and transparent.

Richard Smith, Operations Manager at Atkinson Dyeing, shared that the facility had earlier adopted energy-saving inverters, upgraded to an electric forklift, and replaced its oil boiler with a more efficient gas system, reducing energy use by 64%.

Atkinson Dyeing tracks its progress using a carbon intensity model, which measures emissions for every kilogram of yarn processed. This helps maintain transparency and guides future efforts to reduce emissions. These upgrades support AW Hainsworth’s wider sustainability goals, backed by Planet Mark certification and a clear plan to achieve Net Zero.