More than two years after Cyclone Gabrielle severely damaged its Napier site, New Zealand carpet manufacturer Bremworth (NZX: BRW) is investing $6 million to expand production capacity and restore full domestic woollen yarn production.
CEO Craig Woolford announced that the company is reinstating critical yarn-making equipment at the Hawke’s Bay facility to improve efficiency, product quality, and lead times while maintaining cost-effectiveness and avoiding overcapacity. The upgraded site will operate three shifts, 24 hours a day, five days a week, and up to 40 new employees will be hired to support increased demand.
“Instead of simply restoring the old setup, we’re rebuilding smarter,” said Woolford. “This gives us flexibility to scale as needed while bringing core operations back in-house.”
Previously, due to cyclone damage, Bremworth adopted a hybrid yarn supply model, outsourcing a portion of its production domestically and internationally. The return to full in-house production will allow the company to regain complete control over quality and environmental impact.
The first stage of the equipment reinstatement is set to be operational by end of August, with a second phase following three months later. The improvements are expected to reduce lead times from six months to just six weeks, and cut yarn inventory in half.
“We’re not just rebuilding production—we’re restoring local skills, creating jobs, and building long-term resilience,” Woolford emphasized.
Key site processes like the dye house are already running, and the reconfigured facility will enable Bremworth to respond swiftly to export growth, especially from Australia and the US.
“If demand spikes, we have the capacity to scale up. Each new line takes three months and a significant investment, but that’s a welcome challenge.”
Bremworth is also working closely with the Awatoto Industrial Action Group, along with Hawke’s Bay Regional Council and Napier City Council, to develop a flood mitigation strategy. The initiative aims to prevent future disruptions and has garnered support at local, regional, and national levels.
“This expansion is a win not just for Bremworth, but for Napier and the wider New Zealand manufacturing sector,” Woolford concluded.
