FACTORY bosses were today counting the cost after fire ripped through a carpet underlay firm, pouring thick black smoke across East Lancashire.

More than 10 fire engines attended the blaze at Duralay in Broadway, Haslingden, after fire broke out in a machine at about 3pm yesterday.

The factory was evacuated as crews from Rawtenstall, Haslingden, Bacup and Ramsbottom battled to bring the blaze under control. The incident support unit from Accrington and a turntable ladder from Blackburn were also called in as the flames spread.

At the height of the blaze, smoke could be seen billowing from the site from miles away.

Police also attended the scene as fire hoses carrying water from hydrants across the road caused delays and traffic began to build up along Broadway, which is close to the A56 Haslingden bypass and M66 motorway. Paramedics were also on standby but nobody was injured.

Stuart Tracey, senior divisional officer at Burnley Fire Station, said the machine which caught fire moulds rubber and had set a quantity of lagging and ducting alight, creating blistering heat. Four firefighters wearing breathing apparatus entered the building at the back of the site, which borders the Knowsley Road Industrial Estate and the A56, to contain the flames and stop them spreading.

Mr Tracey said the fire was brought under control in about an hour but the protective material around and behind the burnt-out machine remained hot for some time.

The police helicopter was called in to fly over the site and relay thermal imaging pictures to firefighters, enabling them to pinpoint any areas of extreme heat or smouldering material which needed damping down.

Mr Tracey said Operation Merlin, which links the local authority, police, fire and ambulance services in emergency situations, was put into operation in case roads needed closing or it was decided that the smoke or fire would have a detrimental effect on motorists or householders in the area.

Duralay, which employs more than 300 people, refused to comment.

The firm was formed in May 1996 following a management buyout by BBA Group plc and since then has bought Sponge Cushion Inc, of Illinois, in a £6million deal, and Airstep in Northern Ireland.