British Nylon Spinners
| Company type | Joint venture (initially), later subsidiary |
|---|---|
| Industry | Textile manufacturing |
| Founded | January 1940 |
| Founder | Imperial Chemical Industries (ICI), Courtaulds |
| Fate | Acquired by ICI in 1964 and absorbed into ICI Fibres |
| Successor | ICI Fibres |
| Headquarters | United Kingdom (specific city not stated) , United Kingdom |
Area served | United Kingdom, Australia, New Zealand, South Africa, Germany, United States, Canada |
Key people | F. C. Bagnall (Managing Director from 1945) |
| Products | Nylon yarn |
| Owner | Initially jointly owned by ICI and Courtaulds; fully owned by ICI from 1964 |
Number of employees | Up to 2,500 at Gloucester site; ~1,500 at Doncaster site (dates vary) (1955–1962 (approximate)) |
| Parent | Imperial Chemical Industries (from 1964) |
British Nylon Spinners (BNS) was a UK-based enterprise founded in 1940 through a joint venture between ICI and Courtaulds to manufacture nylon yarn. After an unsuccessful attempt to acquire Courtaulds, ICI gained full ownership in 1964.
Origins
In 1939, ICI secured a license for nylon fibre production and collaborated with Courtaulds, a prominent viscose rayon producer, to utilize their textile manufacturing expertise. British Nylon Spinners was incorporated in January 1940 with equal equity stakes and an initial capital of £300,000. The nylon yarn was crucial for parachute production, especially after Japan’s entry into World War II in 1941 disrupted silk imports. It is probable that government interests encouraged this collaboration.
Courtaulds initiated construction of a manufacturing facility at Lockhurst Lane, Coventry, which began operations in January 1941. Initially, nylon polymer and spinning equipment were sourced from the American company DuPont. The plant endured bombing raids in November 1940 and April 1941, causing temporary suspension of production.
For safety reasons, operations expanded to Stowmarket, Suffolk, where ICI’s Paints Division was located. By June 1943, Stowmarket achieved full production capacity, accounting for two-thirds of total output, while Coventry contributed the remaining third. Both sites ceased operations in 1948.
In March 1945, BNS acquired land at Mamhilad, Pontypool, South Wales. Later that year, F. C. Bagnall was appointed managing director. In May 1947, ICI announced plans for a new polymer plant at Billingham with an annual capacity of 10,000 pounds, primarily dedicated to supplying BNS.
Despite delays in construction materials, the Pontypool factory neared completion by mid-1948. Initial yarn production began in April but faced quality challenges including polymer discoloration and inconsistent yarn quality; these issues required several months to resolve. By September 1948, three spinning machines were operational; full-scale production was anticipated by late 1949 but only fully transitioned to production teams by May 1950. The majority of output was exported under government directives.
The Pontypool site comprised manufacturing and pilot plants alongside a Technical Development Department focused on customer support, administration, and research and development—facilities that remained largely intact as of 2011 near Little Mill.
To support expansion efforts, capital was increased from £6 million to £8 million in February 1949.
Operations and Expansion
In 1950, BNS implemented price reductions exceeding 20%, attributed to higher production volumes and process improvements. Courtaulds observed that BNS was operating near full capacity and planning further expansions aimed at maintaining profitability while both Courtaulds and ICI anticipated returns on their investments. Significant progress had been made by 1951 with expansion activities continuing through 1952.
In 1952, BNS successfully defended its nylon manufacturing rights against a United States legal challenge concerning patent ownership originally granted by DuPont to ICI and exclusively licensed to BNS. A US court mandated ICI to transfer patents back to DuPont, which would have endangered BNS operations. British courts issued an injunction preventing ICI from complying with the US order, thereby protecting BNS’s commercial agreements; this ruling was upheld upon appeal.
In 1953, BNS provided nylon yarn for specialized garments used during the British Everest expedition. That year also saw the acquisition of a former British Bemberg Ltd factory in Doncaster, converted for nylon yarn production. Operations commenced in 1955 with approximately 350 employees, growing to around 1,500 staff over time.
Managing director Bagnall announced price cuts in 1954: a 15% reduction for fine denier nylon yarn and a 10% cut for staple yarns, positioning BNS products as the most competitively priced worldwide.
Between 1955 and 1963, purpose-built clubhouses were established at Pontypool, Doncaster, and Gloucester to serve as cultural and recreational centers for employees.
By 1957, the market offered approximately 40 varieties of nylon stockings with yarn fineness down to 9 denier. That year marked the decision to commence nylon yarn production in Australia. Plans were also unveiled for significant expansions at Doncaster Works aimed at increasing the workforce by up to 600 employees and investing between £3 million and £4 million; completion was targeted for late 1958. A specialist team was recruited to enhance expertise in nylon staple fibre manufacturing.
In December 1957, BNS developed an elasticised yarn that allowed manufacturers to offer stockings in only three sizes.
In 1958, the Royal Navy equipped its new frigate HMS Llandaff with nylon and Terylene ropes instead of traditional wire ropes due to their superior strength-to-weight ratio and durability. That same year, BNS submitted plans for a £10 million nylon factory at Leigh Park intended to employ around 2,000 workers; however, the Board of Trade declined approval citing regional priorities elsewhere. Efforts were made to redirect investment towards Scotland amid concerns about local unemployment.
Delays in the arrival of new nylon-twisting machinery at Doncaster resulted in skilled workers being temporarily reassigned to unskilled tasks.
In 1962, BNS purchased a site near Gloucester that employed up to 2,500 workers displaced by the closure of Gloster Aircraft Company.
BNS produced internal publications including the weekly Signpost, renamed Fibres Post in 1965, along with a monthly BNS Magazine.
On an international scale, BNS operated subsidiaries across Australia, New Zealand, South Africa, Germany, the United States (in partnership with ICI and Celanese), and Canada; these ranged from manufacturing plants to sales offices.
ICI acquisition attempt
In 1962, ICI launched a bid to acquire Courtaulds, which Courtaulds opposed and eventually successfully resisted. Despite this, discussions persisted, and by April 1964 both firms advised their shareholders to accept a proposed agreement. As part of the deal, ICI consented to relinquish its 37.5% ownership in Courtaulds and committed to paying £2 million annually over five years to aid Courtaulds' nylon research and development. In exchange, Courtaulds transferred its 50% interest in BNS to ICI. Subsequently, BNS was absorbed into ICI Fibres, a division specializing in polyester manufacturing.