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Case Studies: TBA Textiles

Overview:

TBA Textiles, a leading manufacturer of industrial textiles based in Rochdale, has identified over £640,000 in potential resource efficiency savings with support from the Business Growth Hub. 

 

The company has over 140 years’ experience in the manufacture of high-performance textiles and is a world leader in heat resistant textiles for applications such as thermal protection products, protective clothing and composite reinforcement.

The challenge:

In 2012, TBA underwent a full factory move to more modern premises and is committed to continually improving its efficiency to help keeps costs down and reduce its environmental impact.

 

In particular, reducing energy demand is high on TBA’s priority list as it is already consuming close to its supply capacity for electricity and gas. 

The solution:

To help identify ways to improve electricity and gas efficiency and find other resource savings, TBA received specialist resource efficiency support from the Growth Hub’s Green Growth team. 

 

Claire Scott, a Green Growth environmental business advisor, conducted several resource efficiency reviews of TBA’s premises, including a thermal imaging survey and electricity logging of key equipment.

 

Opportunities identified from these reviews included:

  • Minimising heat loss by fitting thermostatic controls in offices and investing in radiant heaters and destratification fans
  • Upgrading lighting to more energy efficient technologies
  • Fitting key production equipment with variable speed drives 
  • Exploring voltage power optimisation technology to reduce power demand
  • Preventative maintenance and compressed air leak detection
  • Investing in new packing machines to improve packaging efficiency by removing air from products
  • Introducing laser cutting and optimisation software to fabric cutting processes to increase production efficiency and reduce waste.

TBA also identified further opportunities to improve efficiency by bringing more manufacturing in-house. This could potentially save over £400,000 a year whilst improving product quality and freeing up warehouse space that is currently dedicated to bulk storage of imported materials. 

 

In total, the opportunities identified by TBA and the Green Growth team have the potential to save £649,000 in costs and 252 tonnes of carbon dioxide equivalent (CO2e) per annum. The majority of these opportunities will pay back on initial investment in less than two years.

 

“TBA Textiles is a successful company that has become a leader in its field. Ensuring high-efficiency production is a key part of maintaining this position in the market, so our resource efficiency support fits well with that”, said Claire Scott.

 

Mark Lineker, general manager at TBA Textiles, said: “Since moving to new premises in 2012 we’ve worked hard to maintain and continually invest in high-efficiency manufacturing, and the fact that we’ve identified over half a million pounds worth of efficiency measures demonstrates the value of having a service like Green Growth on board.”

 

“Our next step is to investigate which of these actions we should prioritise, and we look forward to ongoing support from the Business Growth Hub to help us progress across our business.”

 

Further support from the Business Growth Hub

TBA has also been able to access further specialist Growth Hub support, including the Executive Development Programme which involved a 3 day Inspirational Leadership course for two members of the team that needed support with business planning, self-management and presentations.

 

The Textiles Growth Programme has also supported the business through a grant of £96,400 towards a capital equipment purchase project of £530,000. This allowed TBA to purchase four looms, a hot melt line, a needling machine and a friction spinning machine and upgrade of two pieces of equipment.  This new and upgraded machinery will create 14 new jobs including four apprenticeships ultimately helping them to move forward with plans to bring more production in-house.

“The fact that we’ve identified over half a million pounds worth of efficiency measures demonstrates the value of having a service like Green Growth on board”

TBA Textiles
Business Growth Hub

Churchgate House
56 Oxford Street
Manchester
M1 6EU

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