New technology will cut emissions from wool carpet manufacturer by 30%

One of the country's largest wool carpet manufacturers is set to cut its carbon dioxide emissions by up to 30%.

Bremworth's Napier wool yarn spinning plant is getting a $2.1 million upgrade which will see it transition from using natural gas to electric heat pump technology during part of its dyeing and finishing process.

It's a move which will see them reduce emissions of up to 1,500 tonnes of CO2 per annum – the equivalent of planting between 800 and 1500 radiata pine trees.

The wool and natural fibres manufacturer is also looking cut carbon dioxide equivalent (CO2e) greenhouse gases a further 197 tonnes per year by installation a radio frequency dryer using radio waves to dry woollen yarn during the production process at its Whanganui plant.

READ MORE: * Cavalier accused by rival of 'demonising' synthetic carpets * Wool farmers see potential salvation in new products for builders, architects * Moral fibre: Why sheep farmers want Kiwis to take another look at wool * Big Save Furniture pays twice the price for strong wool * Wool carpet market share grows for first time since the 1990s * The most carbon-conscious companies and what they are doing to reduce emissions

Chief executive Greg Smith​ said of the two main greenhouse gases produced in New Zealand – carbon dioxide and methane – manufacturing industries were one of the biggest CO2 emitters with the largest annual increase in emissions.

About one third of the country's overall energy use stems from industrial heat processes, according to the Energy Efficiency and Conservation Authority. Of this an estimated 60% of production heating is fossil-fuelled.

Decarbonising energy supplies was a key part in tackling climate change, Smith said, adding businesses had to play a leadership role in this.

He said it was a really strong start for the company and one which they were excited about.

The move to using electric heat pump technology in Napier will improve the energy efficiency of manufacturing processes, by detailed process heating measurement, minimising waste heat and optimising the heating system configurations.

This will also help boost production and exports, Smith said.

"This initiative has a direct impact on the amount of carpet we can produce and consequently will help us increase export volumes. The production gains from the new technology will complement the planned site capacity increases which will also take place over this time period."

A group of specialist engineers and contractors to build and install the new technology at the Napier factory over a 24-month period, while it is hoped the radio frequency dryers will be in place at Whanganui, where they make felt, from 2023.

The project is being part funded through the government's Investment in Decarbonising Industry (GIDI) Fund, administered by the Energy Efficiency and Conservation Authority, which is contributing close to $800,000.

Smith said this model of funding was the way to go in helping encourage other businesses decarbonise.

"The adoption of new energy efficient technologies has a significant role to play in reducing emissions from New Zealand's industrial manufacturing sector and it is critical that organisations accelerate their introduction."