Ulster Carpets’ new Dye House and Energy Centre, situated at the company’s headquarters in Northern Ireland will not only facilitate a number of manufacturing efficiencies, it will also bring with it many environmental benefits in line with the company’s Sustainability Policy.

A dedicated building, state-of-the art technology and a complete move to package dyeing from hank, will increase capacity and improve the efficiency of the whole process providing faster response times.

The new dye house will deliver 20% more efficiencies than the building and processes that it replaces. This is mainly due to new a automated dispensing system that allows more accuracy on the weighing of dyes and chemicals.

Ulster Carpets, Dyehouse & Energy Centre, January 2018 from Ulster Carpets on Vimeo.

New technology means that cycle times are reduced by eliminating the requirement to neutralise each dye lot as it is processed, therefore producing more dye lots per day.

Package dyeing uses considerably less water (40%), heat (25%) and chemicals (5-10%) per kilogram of yarn processed, and the system’s capabilities means a greater amount of dye lots can be produced in one day, making the new dye house more energy efficient.

At present, while much of the water used in the dye process is taken from Ulster’s own borehole, the rest comes from the local town supply. A reduction of 40% in water requirements minimises usage from the town supply reducing the environmental impact of the dye house on the local area.

The building has been designed and constructed by local businesses. This is a deliberate strategy by Ulster Carpets, supported by Invest NI, to continue to invest in Northern Ireland’s economy and to support local jobs.

Ulster Carpets was delighted to be included in the latest article by PWC ‘Changing Times’.

Next year, Ulster Carpets will celebrate 80 years of carpet manufacturing. Dedicated to producing the finest axminster and wilton products, to this day the family owned company remains committed to the original Ulster ethos based on growth and development. Whilst tough trading and financial periods have seen many of their competitors move their operations abroad, Ulster’s long term strategy and proactive business approach has enabled them to withstand the crisis and ensure all wilton and axminster manufacturing remains within the UK and Ireland. From the buying and processing of the wool in Ulster Yarns in Dewsbury, to the winding, dyeing and weaving at the Castleisland site in County Armagh, Ulster have control over every aspect of the process ensuring the quality of the carpet is of the highest standard.

People are at the heart of Ulster Carpets and it is the passion and dedication of its employees that sets them apart from the competition. Continuous demand for their products around the world, combined with expansion into new export markets has led to a recent increase in employment levels with 20 new jobs being created, providing a welcome boost to the local economy. Each year Ulster also runs a graduate scheme, taking on students across all areas of the business including design, sales, engineering and operations.

Technology and innovation is part of the Ulster Carpets’ ethos. Their patented PSYLO™ technology, which allows designers to use a superior number of colours without the need for a repeating pattern, has enabled them to become a market leader in the manufacturing of bespoke Axminster designs for the hospitality, cruise liner and casino markets. To date they have supplied some of the world’s most famous venues including the Ritz Paris, The Regent Fleet Seven Seas Explorer and the Burj Arab Hotel in Dubai.

In addition, investment in infrastructure plays a huge role in their growth and development. As part of a £35 million regeneration of all woven manufacturing facilities at their Northern Ireland headquarters, last year saw the completion of a brand new state-of-the-art Dye House and Energy Centre, designed to improve energy efficiency and reduce the company’s carbon footprint. The remaining phases of the redevelopment will be rolled out in the coming years.

Nick Coburn, Group Managing Director and Deputy Chairman commented:

“Ulster’s continued focus on innovation and investment has enabled us to grow and maintain our competitive advantage. We are a family owned, but professionally managed business committed to operating as a vertically integrated, self-sufficient company in order to maximise our control over the entire manufacturing process. This will ensure we continue to strengthen our position as a premium carpet brand in the years to come.”

Read the full article on PWC’s website