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China investments include the installation of two electric( rather than gas) glazing pre-heaters, which has resulted in an 80 percent reduction in kilowatt hours, as well as an upgraded burner replacement and a new VDS compressor with smart link capability.
The installation of solar panels has played a key role in Churchill’ s energy efficiency strategy. The company trialed solar with the installation of 232 panels in 2019, before adding a further 405 panels in 2021. In 2022, a further £ 1.4 million was invested to install 4500 panels, resulting in an average lifetime saving of 901 tons. Churchill applied to install an additional 5000 panels, but the application was refused until 2033 due to infastructure on the National Grid.
For kilns, the company has invested in its kiln car structures to increase the amount of product on each car. With kilns accounting for 84 percent of Churchill’ s total gas usage, the business has engaged with several kiln manufacturers to target future solutions of
tableware firing. Natural gas is still viewed as the optimal fuel, as electric tunnel kilns are unproven and running costs are too expensive. While hydrogen firing is feasible, with Churchill having test fired a 100-percent hydrogen plate and become a member of the Hydrogen Valley consortium, the lack of supply and safety concerns remain major barriers to this technology.
Aside from internal investments, James is keen to highlight that the UK Government could do more to support UK ceramics businesses.“ It is essential for the industry that there is no increase in gas commodity charges ahead of support on electricity and a viable route to electrification, including network capacity,” James states.“ Support could also be provided through interest free loans for UK capital projects relating to automation, productivity, and further decarbonization. This is a well-trodden route in markets like Germany, as it strengthens local industry at a very low cost to the taxpayer.
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