Efficient production processes

Wienerberger’s high-quality building material and infrastructure solutions are in high demand worldwide. We are committed to using efficient processes and innovative technology during the manufacturing process. We are continuously improving our processes in all three production areas – ceramic, plastic and concrete. Environmental, social and economic factors are equally important to us. With these in mind, we will make our production even more sustainable and improve the quality and features of our products.

Clay is the most important raw material in the production of ceramic. We use it to manufacture Clay Blocks, Facing Bricks, Roof Tiles and Ceramic Pipes, as well as Clay Pavements. After the clay has been mined, we prepare it in an automated process that adds water and sand. For certain products, we also use pore-forming agents, such as sawdust, straw or sunflower seed shells. This enhances the bricks’ heat insulation qualities. Following this, the clay is pressed into shape by extruders and cut into pieces or shaped in an automated process. At the end of the process, the products are dried, baked and packaged.

We are committed to using environmentally friendly techniques at every stage of the process. We adhere to very strict criteria when choosing the locations where we mine clay. We consider how we can preserve resources at these locations and how to use these quarries after the clay has been mined. Thanks to the proximity of clay quarries and manufacturing locations, materials do not need to be transported far. The waste from the production of ceramic is easy to recycle. Our number one priority during the drying and baking processes is to use renewable energy and energy sources which produce the lowest possible emissions. In addition, we are continuously evaluating how we use renewable energies, such as biogas from local sources. We use recyclable materials and the minimum packing for our products.

In the production of Plastic Pipes and their component parts, Wienerberger considers plastic granules to be the most important material. They are melted at temperatures of around 200 degrees Celsius. They are heated in an extruder, which shapes the hot mass of plastic into pipes by flowing it into a die. A calibrator ensures it has the desired diameter, which can range from as little as several millimeters up to 2.5 meters. After this, the pipe is placed in a pool of water, where it is cooled and cut. Here, you can find pipes as long as 600 meters. Finally, the products are packaged and delivered to our customers.

In the production of Plastic Pipes, we only use materials which do not pose a threat to the environment either during the manufacturing process or when in use. Plasticisers are not used. We also take further measures to protect the environment: Thanks to the use of electricity, no direct CO2 emissions are produced during this process. We have set ourselves a clear goal of increasing our use of recycled materials. Furthermore, we only work with closed water circuits systems and only use our own sources for water. 

Concrete is manufactured from cement, sand, aggregates and water. Wienerberger obtains the raw materials for making pavements from local manufacturers and according to established quality standards. After the mixing process, the different parts are shaped via pressing or casting and are left to harden at room temperature for about 24 hours. Certain products undergo additional refining processes, such as washing, sanding, sandblasting or coating. The finished results are packaged and sent out for delivery.

Likewise, manufacturing concrete surfaces does not require much energy. Our machines are only powered by electricity. To improve the process, we are always pushing for further research and development. Our focus is on reducing the amount of cement in the concrete. As well as this, we are continuously implementing new measures to be more efficient with our resources and to control waste management. In addition, when using closed water circuits, we are committed to using as little water as possible. Anything left over from the production process is usually fed back into the circuit.

The manufacturing process is an important part of how we add value to Wienerberger. We have set ourselves a clear goal: we will improve the value of our business where environmental, social and economic factors are concerned. Thanks to our manufacturing business, there are innovative solutions to traditional building materials: from sustainable and energy-efficient buildings, to durable pavements, to safe pipe systems.