Bremworth builds back better after Gabrielle
Bremworth’s $6 million factory rebuild near Napier is a win not only for the company itself, but for the city and New Zealand manufacturing as a whole, says CEO Craig Woolford.
Key processes, including the site’s dye house and other lines, are already operational. The first stage of the current equipment reinstatement is expected to be operational in a few weeks, with a second stage three months later.
Woolford says the company plans to operate three shifts 24 hours a day, every weekday, and will hire up to 40 new staff to accommodate expected demand. “We’ll also be rehiring a range of specialised staff in the process. It’s not just about rebuilding production but also restoring local capability, building resilience and bringing jobs back to Hawke’s Bay.”
The big investment is expected to dramatically reduce lead times, from up to six months down to six weeks, and cut yarn inventory by half, while allowing the company to take full control of yarn quality again.
As a result of Cyclone Gabrielle more than two years ago, most of Bremworth’s Hawke’s Bay carpet facility at Awatoto was taken offline. “To maintain carpet production, we introduced a hybrid yarn supply model which saw increased quantity of our yarns processed externally, including offshore. Rather than just reinstating everything, we’ve taken the opportunity to rebuild smarter – in the process, allowing us to ramp up yarn capacity as demand grows,” says Woolford. “We’re bringing back the core pieces of equipment needed to give us flexibility and headroom while keeping costs down. The reinstated capacity brings Bremworth back to full operational strength, with both mills going to be able to meet current demands and support the company’s plans to scale for growing international demand.”
Woolford says the reconfigured site gives Bremworth the ability to scale quickly in response to export growth, including new interest from the US and Australian markets. “If demand spikes, we’ve got capacity we can activate. Each new addition takes about three months and hundreds of thousands of dollars to bring online, but that’s a good problem to have,” he says.
Bremworth has already begun phasing out its temporary hybrid yarn supply model and plans to bring yarn production fully back into its own New Zealand facility. Woolford says the move aligns with the company’s focus on quality control and environmental impact. “We’re proud of what we are doing. It’s a win not just for the business, but for Napier and the wider New Zealand manufacturing story.”
Bremworth is working with industry group, Awatoto Industrial Action Group, to develop a flood mitigation solution in conjunction with the Hawke’s Bay Regional Council and the Napier City Council to prevent a repeat of the impact to the business community in that location following Cyclone Gabrielle. This initiative has local, regional and national government support.