Yorkshire Textile Dyeing Firm Cuts Carbon Footprint

Yorkshire textile dyeing firm cuts carbon footprint with innovative heat recovery system called Atkinson Dyeing, a specialist yarn dyeing facility established in 1978 and acquired by woollen mill AW Hainsworth in 2019, has undergone significant transformation to improve environmental performance and modernise operations.

The centrepiece of this transformation is the installation of a state-of-the-art heat recovery system, which captures 60°C wastewater and uses it to preheat incoming cold water to 50°C.

This system is designed to reduce the site’s reliance on gas, delivering a major reduction in carbon emissions. At its full potential, this is projected to lower the facility’s gas bill by 20% and electricity by 10%.

This investment builds on a range of infrastructure and operational improvements made across the Atkinson Dyeing site in Keighley. The winding area has been upgraded to increase efficiency, featuring the installation of 3D fans to reduce dust and improve air quality, a new insulated roof, upgraded LED lighting, and new windows that increase natural light.

Reusable cones continue to reduce plastic waste, while new, in-house-engineered yarn-stripping machines have improved speed and process control. The site also introduced computer-controlled dyeing machines, which reduce water consumption compared to traditional methods.

Water and chemical management has also been a priority. The site utilises river abstraction rights to reduce its reliance on mains water and ensures that all used water is treated offsite, with no discharge returning to the river. To mitigate environmental risks, bunds have been installed beneath chemical storage areas to contain any potential leaks. There has also been a focus on recycling and reuse efforts, with all cardboard, plastic, and wood being recycled and repurposed where possible.

On the technical side, Atkinson Dyeing has implemented an OrgaTEXcloud-based planning system to enhance production traceability and scheduling across departments.

Richard Smith, Operations Manager at Atkinson Dyeing, commented:

“In previous years, we’ve installed power-saving inverters on our machinery, switched to an electric forklift truck, and converted the oil powered boiler to a more efficient gas burner, which reduced energy usage by 64%."

“We still have a long way to go, but we’re proud of the progress made at Atkinson Dyeing. From facility upgrades to innovative technology and sustainable practices, we are continuously investing in our long-term vision for growth, environmental responsibility, and workplace wellbeing.”

The facility’s progress is closely monitored using a carbon intensity model that tracks emissions per kilogram of yarn processed. This method allows the team to maintain high levels of transparency and accountability while setting a clear baseline for future reductions. The improvements at Atkinson Dyeing form part of AW Hainsworth’s broader sustainability strategy, which is supported through Planet Mark certification and a formal roadmap towards reaching Net Zero.