Billingham and Wilton manufacturing history

 In 1917, the village of Billingham in County Durham suffered the agonies of the First World War as the rest of the country where young men joined up never to return - from Bellingham some 137 died; the population was 4,599. For Billingham, the war would result in massive physical change - A Brave New World.

The world war in which the country was engaged placed huge demands on industry. In particular the young chemical industry would undergo a revolution in order to manufacture the vast quantities of explosive which the shell filling factories were demanding. Brunner Mond of Northwich in Cheshire were asked to increase their production and in 1916 a new purpose built factory at Stratton in Swindon was dedicated to the production of nitrates.

It was a year later that the Ministry of Munitions commissioned the building of a yet larger plant at Billingham transforming the landscape. The plant was not in production by the end of the war, but in 1920 Brunner Mond formed Synthetic Ammonia and Nitrates Ltd to make ammonia for use in explosives but also ammonium sulphate fertiliser. The plant has access to a substantial bed of anhydrite a form of calcium sulphate which made it a suitable place for the production of ammonium sulphate. More significantly for the Ministry of Munitions, the plant had access to electricity from a soon to be commissioned station by the Newcastle Electricity Supply Co. With the coming of peace, there were severe doubts as to the market for nitrogen based chemicals and there was lengthy debate and negotiation with potential partners. But Brunner Mond did go ahead and set in stone the location of the heart of the soon to be born ICI .

The plant attracted chemists from around Britain including a young Aldous Huxley to whom Billingham represented an 'ordered universe in the midst of a wider world of planless incoherence'. It was ground breaking technology which, by the time Huxley arrived, was focused on the production of fertiliser to feed a hungry world. The world, though, had changed and other countries were equally able to produce the fertiliser they needed. Billingham had to look further afield.

In 1926 Brunner Mond became part of ICI and spurred Billingham to further growth. By 1932 it employed 5,000 out of the then population of 18,000. The Second World War renewed the demand for explosives. Billingham produced a high octane fuel from creosote which had added 25 mph to the top speed of a Spitfire in pursuit of German flying bombs.

A key invention was that of Perspex which proved ideal for the windscreens of Spitfires. Later other plants produced Perspex including Darwen in Blackburn, Lancashire.

In 1945, the company bought the site on which it would build its other major plant in the north east at Wilton. This was not only bigger, but would be home to Britain’s major chemicals manufacture for decades. It had its own power plant, with 33MW Metropolitan Vickers/AEI turbine-generator sets powered by Babcock and Wilcox boilers. It was vast then, but in 2013 boasted sixty miles of road, four hundred miles of electric cable and one hundred and fifty miles of pipework on the two thousand acre site. In the late forties and fifties, its production included nylon, terylene and perspex.

The postwar world saw the explosion of petrochemicals whereby a 'cracker' splits crude oil into its constituent chemicals. ICI’s cracker at Wilton was itself linked to Billingham by a ten-mile pipeline, making it the largest chemical plant then in the world. ICI Acrylics division would go on to produce the feedstocks for plastic manufacture and much more.

Further reading:

W.J. Reader, Imperial Chemical Industries - A History Vol II The First Quarter Century 1926-1952 (London: Oxford University Press, 1975)

Northwich manufacturing history

 The wich-es in Cheshire, Northwich, Middlewich and Nantwich have provided salt for centuries along paths known as salt ways, like the one by which I live in Leicestershire.

For two young chemists in the late nineteenth century they held rather more: the promise of soda ash for which the cotton manufacturers were screaming.

John Brunner and Ludwig Mond had met whilst working for Hutchinson’s alkali works in Widnes. They gained backing from wealthy engineer Charles Holland and bought Winnington Hall in the grounds of which in 1874 they built a plant producing soda ash by the then new ammonia soda process, The Solvay Process. Three further plants followed. The Solvay process gained acceptance over the former Leblanc process because it reduced the pollution of the latter and was altogether more efficient.

In 1926 Brunner Mond joined United Alkali, Nobel Industries and British Dyestuffs to become ICI and the enlarged company committed itself to research. They founded a laboratory on the site and it was there in 1933 that polythene was first produced. The Winnington works continued with polythene until production was transferred to ICI Hertfordshire.

Winnington was a significant part of the ICI Mond division and is now part of Tata Chemicals Europe and continues with soda ash manufacture. In 2022 Tata set up the first industrial scale carbon capture site in Europe.

Winnington Hall was previously a girls boarding school to which Victorian writer John Ruskin visited to lecture on one of his books on political economy.

Runcorn and Widnes manufacturing history

 These towns facing each other over the Mersey share an industrial history of chemicals manufacturing. They were joined by a transporter bridge in 1905 which was replaced by the arched Jubilee Bridge in 1961.

The opening of the Bridgewater canal in 1776 kick started industry in Runcorn. Two large soap and alkali works (Hazlehurst and the Runcorn Soap and Alkali Company) were destined to grow throughout the nineteenth century, particularly with advances in science in mid century. Proximity to the sea and canals encouraged shipbuilding and the presence of minerals underground enabled lead and copper mining.

The opening of the Manchester Ship Canal in 1895 further improved the connectivity of the town and the Castner-Kellner company (which later became part of ICI) began using the electrolytic process from which both caustic soda, bleaching powder, chlorine and hydrogen were extracted. The Hazlehurst soap business was bought by United Alkali, of which I say more below, who then sold to Lever Brothers (later Unilever) adding to their soap business. The town became home to British Dyestuffs also later part of ICI which located the headquarters of their Mond heavy chemicals division there.

ICI's Fluor produced fluorocarbons, used as refrigerants in air-conditioning systems in cars and homes, at sites in Runcorn, Japan and Louisiana. The company's Chlor's Runcorn site dated back to 1800s and the first industrial production of chlorine. Since then, regulations had tightened and the market had wilted, leaving a plant full of ageing and poorly maintained equipment. One comparison is quite eye opening. Its enormous cell room took as much electricity as the whole city of Liverpool. Both companies together with Crosfield of Warrington were bought by Ineos.

A river, a ford and a sunny south slope were the attractions of the place that became Widnes. What was a pretty village came to be a major chemical town through the initiative of John Hutchinson when the cost became prohibitive of taking raw materials (salt) from Northwich in Cheshire to St Helens where there was coal to produce soda and the potassium chlorate and bleaching powder. Widnes had local supplies of coal, easier access to the Cheshire salt fields abundant land and good communications by canal and railway. Hutchinson was joined by Gossage, making washing soda by the Leblanc process, and it was not long before huge amounts of sulphur infested chemical waste was being dumped on the Widnes wet lands. It was a German immigrant Ludwig Mond, a friend of John Brunner who worked with Hutchinson, who discovered a process capable of removing half of the waste sulphur. Soon this was widely adopted. Henry Deacon who had been working with Hutchinson formed a partnership with Gaskell to make sulphuric acid and ammonia soda used in the less polluting Solvay process with a bi-product of calcium chloride.

The pollution from the chemical works combined with inadequate sanitation led to Wides being called 'the dirtiest ugliest town in England'. The growth in population was boosted by immigration from Ireland of people fleeing the famine. The poor living conditions led to men seeking solace in alcohol and the town gained bad reputation which disappeared into memory as the town was improved.

United Alkali was formed by the merger of forty-eight alkali producers including fourteen from Widnes with the remainder based in St Helens, Tyneside, Scotland and Ireland. Old polluting plants were closed. United Alkali became part of ICI. Brunner and Mond joined together in 1873 but at Winnington near Northwich in Cheshire producing soda-ash for the cotton industry also using the ammonia soda process.

In Wides, John William Towers joined Hutchinson's laboratory in 1872. He then joined the Atlas Chemical Works set up by James Hargreaves and Thomas Robinson to exploit the salt-cake process and Towers went on to produce scientific apparatus for the chemical industry. Further chemical companies set up plants: Alumina Ltd, Peter Spence & Sons and Barium Chemicals. I write more about the consolidation of the chemical industry in Vehicles to Vaccines.

Andrew Poulson came from Wigan in 1869 to the Widnes foundry and took charge of the moulding department producing cast iron pillars which were used in pier construction amongst others, and segments for lining the London underground. The town, like others around, had copper foundries including Thomas Bolton's Mersey Copper Works producing copper rods and plates for locomotives and also rollers for calico printing; later it would supply the electrical industry. British Insulated and Helsby Cables was nearby and became part of BICC. High Speed Alloys was established in the town to produce special grades of steel, it was part of a merger of some eighteen similar businesses. Bell's Poilite and Everite Company manufactured asbestos cement of corrugated roofing.

The First World War made great demands on the chemical manufacturers and iron and steel works, the latter including for masts for Marconi Radio. The twenties saw consolidation of the chemical industry with the formation of ICI. Albright & Wilson set up on the site of the former Musgrave Works and Fisons took control of Vickers Fertiliser.

In the Second World War the Central Laboratory in Widnes carried out research into Uranium in support of the nuclear bomb project. The production of artificial rubber for insulation was undertaken and the metal works made Bailey Bridges.

In the post war world, Widnes industries focused on chemicals, asbestos and gelatine for sweets,

Runcorn was designated a New Town in 1964 and attracted General Motors which then closed in 1991, Sigmatex (carbon fibre textiles) Héroux-Devtek (aircraft landing gear), Whitford (speciality coatings), Teva (pharmaceuticals), and Fresenius Kabi (medical products). Diageo also maintains a packaging plant in Runcorn. Runcorn and Widnes became part of Halton Borough Council in 1974.

Further reading:

• https://www.millbank.com/blog/chemicals-north-west-past-present-future
• Charles Nickson, History of Runcorn (London: Mackie and Co, 1887)
• George E. Diggle, A History of Widnes (Corporation of Wides, 1961)

You can read more in Vehicles to Vaccines and in How Britain Shaped the Manufacturing World 

Huddersfield manufacturing history

 Huddersfield provided a commercial centre at its famous Cloth Hall for the many thousands of home working wool weavers in the surrounding district. 

The inventions of which I have written elsewhere slowly changed this settled and quite prosperous scene. In his book The Story of Huddersfield Roy Brook first points to  the error in assuming that wool and cotton were distinct industries. He makes the point that ‘Manchester Goods’ (which incidentally my father traded in East Africa in the early twentieth century and of which I wrote in my book Dunkirk to D Day. The image is of my father on Mombassa railway station in 1911) were a mix of cotton and wool. Similarly the weavers and spinners of Huddersfield almost certainly worked with cotton as well as wool. 

In terms of mechanisation, the first initiatives increased the speed of spinning and thus the weavers had somehow to keep up. I have read elsewhere that exports of thread to the Low Countries balanced the overproduction, but was not welcomed. Mechanisation of weaving had a more dramatic impact, for now factories filled with weaving machines could and did replaced the many thousands of hand weavers. The well known opposition of the Luddites was replicated across the wool weaving areas. Charlotte Bronte’s book Shirley offers a vivid account of what this might have been like. Mechanisation was in fact a gradual process with hand weavers providing cloth along side the much larger mills. 

Huddersfield did have its weaving machine manufacturers, but, for worsted cloth, manufacturers from the west of the Pennines were used, worsted having greater similarities with cotton cloth. In Huddersfield, Haighs were well known for carding engines. Whiteleys became famous for the manufacture of spinning mules and tentering machines. 

Huddersfield developed a chemical industry on the back of dye houses. Read Holliday began with dye but then moved into acids including picric acid which would become essential in the Great War as would lyddite. War also presented a challenge, for German produced materials were key in the supply chain. In time home production took the strain. The company became first part of British Dyestuffs and then of ICI. It is now run by Syngenta.

The introduction of the steam engine, about which Samuel Smiles wrote so engagingly in his Lives of Boulton and Watt, had a dramatic impact on Huddersfield as it had in other textile areas. Broadbents led the field in Huddersfield in steam powered heavy machinery. Hopkinson became well known for their ‘Indicator’ which could tell the operator how a steam engine was performing, highlighting hidden areas where problems may be arising. It was compared to stethoscope for a physician. 

Machinery manufacturers engendered skills applicable in other fields of mechanical engineering, an example being plant for the production of gas.

Karrier trucks were made here and later became part of the Rootes Group.

The introduction of electricity brought about further change and it was Ernest Brook Limited which manufactured electric motors for use in factories. In November 1950, the company produced its millionth engine.

David Brown Gears began in 1860 serving the wool industry and it grew to having fourteen factories with 10,000 employees. I write of its activity with tractors in the Second World War in How Britain Shaped the Manufacturing World. It went on to lead Aston Martin Lagonda to great success. It continues to do great engineering as David Brown Defence.

Further reading 

Roy Brook, The Story of Huddersfield (London: MCGibbon & Kee, 1968)

Hull manufacturing history

 ‘It presents the eye an interesting spectacle of numerous vessels floating to and from the port of Hull: while that opulent and commercial town in its low situation close to the banks and surrounded by the masts of the shipping in the docks seems to rise like Venice from amidst the sea, the whole comprising a scene which for beauty and grandeur can scarcely be exceeded.’

This quotation from Bradshaw’s Guide had, behind it, a profound change in the lot of the British home. The railway had opened the inland but had also made accessible the shore to inland dwellers, and, in particular, had brought to the tables of ordinary people food never previously dreamed of. Hull, which had been a home of whaling, became the home of the British fishing fleet landing vast quantities of cod and haddock which would be whisked away by railway train to all parts of the country. That though is for later in the story.

Hull was first and foremost a port. In his book History of Kingston upon Hull, Hugh Calvert writes that Hull along with Liverpool were the major ports serving the Industrial Revolution and so were busy with both imports and exports. Hull at the mouth of the Humber was by the eighteenth century linked by rivers to Sheffield, Leeds, Huddersfield, Wakefield and Halifax. Soon canals would also link to Birmingham, Derbyshire, Nottinghamshire, Staffordshire and Leicestershire and East Lancashire. Exports comprised iron, lead and metal goods but also pottery, hosiery and beer. Imports were of Swedish and Russian iron, timber, corn, linseed, flax, turpentine and tar. The Continent of Europe was the major destination but Hull also competed with Liverpool for the trade with America. With trade grew banking and the Smith's Bank also in Nottingham and Lincoln was just one of the progeny.

Shipbuilding had flourished in Hull since the fourteenth century or even earlier. Ships built included whalers, ships for the carriage of wine and naval vessels. The most important shipbuilder by the eighteenth century was the Blaydes family. Notoriously, a Hull shipyard built the Bounty later known for the mutiny against Captain Bligh. Steam and iron came successfully to Hull at the hands of the Earle family. In terms of shipping companies, it was the Wilson family that took pride of place.

The Earle family was also responsible for bringing the making of Roman Cement to Hull just three years before the invention of modern Portland Cement in 1824. The company would become part of the Blue Circle Group.

Manufacturing was the order of the day and Hull was not to be left out. It tried mills for both flax and cotton, but neither took off. Seeds for the oil they contained were more promising and factories for rolling and crushing seeds began to be built alongside businesses manufacturing the machinery required. In terms oil for margarine and soap, much later Unilever bought into the local industry. Oil was also used for paint, especially when combined with lead, and a paint industry emerged with Blundells, but also Reckitts which would become Reckitt and Colman manufacturing laundry starch, black lead and household polish.

The latter part of the nineteenth century saw a dramatic increase in the number of ships fishing from Hull. A rich area of fish had been discovered, growing urban areas were seeking sources of food and the technique of trawling for fish had been adopted. Ships powered by steam and then diesel added to the activity as did the invention of a means of making ice. Fish had to be kept cold from the point of being caught up to the point of sale at the fish market, and ice had been imported from Norway to achieve this. The Hull Ice Manufacturing Company began making its own ice in 1891. The Fylde Ice Company may take issue and suggest that its founder Joseph Marr, a Hull trawler man, had begun importing ice in 1860 and his son James set up the Ice Company in Fylde in 1908. That company expanded in to cold storage and still makes ice. One spin off from deep water fishing was the processing of cod liver oil, much 'loved' by those of us of a certain age.

The twentieth century saw Distillers set up plant to produce industrial alcohol and other chemical products of which I write in Vehicles to Vaccines. Smith + Nephew started out in Hull and still manufacture in the town. Hull is also still home to Ideal Heating formed in 1906. In nearby Brough, BAE Systems run the engineering centre for the Hawk trainer. This builds on the legacy of Hawker Siddeley and before then Robert Blackburn who set up the Brough factory at the start of the First World War.

Further reading:

Hugh Calvert History of Kingston upon Hull (Chichester: Phillimore, 1978)