Trico, one of Europe's leading exponents of vitreous enamelling, has successfully completed the 'light-up' of its furnaces following the move from Keighley to its new 6,000 sq metre site at Castlefields Mill, Crossflatts.

The efficient and environmentally clean plant will allow this ambitious company to maintain its pre-eminence as the largest contract enamel plant in Europe.

Previously based at Lawkholme Lane, Trico (The Rustless Iron Company) offers a comprehensive service in vitreous enamel finish for such diverse products as architectural panels, signs and cookware, washing machine tubs, chemical processing tanks, engine exhaust silencers and air cleaners for power generation equipment. Vitreous enamelling is a unique finishing process which fuses coloured glass into a metal surface. It provides durability, style and colour, combining the beauty of glass with the strength of the metal behind it. Trico has over 100 years' experience in vitreous enamelling and can adapt the process to an extensive selection of products.

The need to find a new site came about as a fiercely competitive market put demands on the company which outstripped the aging resources on its 100-year-old Keighley site. Key issues needed to be addressed to maintain the firm's position at the forefront of the industry.

Production techniques needed updating to keep abreast of advancing vitreous enamelling technology, prices needed to be kept competitive in a difficult market and the enamelling process rendered totally environmentally friendly.

Management at the company agreed that a massive investment in new plant and technology was vital, but the Lawk-holme Lane site was too old and inappropriate to accommodate such technology.

A move within Keighley would have been favoured - especially as Trico draws the core of its workforce from the town. But a suitable site could not be found and Trico's management felt a move to Crossflats, only a stone's throw away, was ideal.

The move was a difficult and challenging experience for plant director Edward Gandy and his staff in both monetary and logistical terms.

The special plant and machinery was bought from Thielmann/Teka and chosen for its quality, efficiency and cleanliness.

The machinery had to be shipped from Germany and transported to Castlefields Mill.

, where it was modified, assembled, tested and made ready for production just as the Keighley plant was scaling down.

Having overcome the problem of rematching services and utilities, Mr Gandy and his team are delighted with the new plant and the huge potential it offers. Housed within what was originally a cotton mill, built in 1758 and with Class 2 Listed office buildings, the Castlefields Mill site and the newly installed plant offer considerable benefits in terms of energy saving, efficiency, ergonomics and the environment.

The exhausts used to channel dust away from the buildings are so efficient that exhaust air from the production process is suitable, after scrubbing, for heating the whole site. Ninety per cent of waste water is recovered for recycling, and the central building contains a single span of 40 x 40 metres, ideal for housing the new plant in one designated location. Just as important, the company says the plant has no adverse environmental impact at all.

With the production line gaining momentum and new products and new customers likely in the near future, Trico is confident it can fulfil its potential for its employees, the local community and its shareholders.

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