Bosses at an East Yorkshire roof tile manufacturer have celebrated a landmark moment as construction begins on a world-first kiln as part of a multimillion-pound investment.
World's First Fully Electric Tunnel Kiln
Wall, roof and landscaping specialist wienerberger UK and Ireland has broken ground on the world's first fully electric tunnel kiln, which will be used to produce clay roof tiles at its Broomfleet site in East Yorkshire. The company, which also operates out of Killingholme, said the move represents a significant milestone in its long-term decarbonisation strategy and its ambition to revolutionise heavy clay manufacturing.
How the Electric Kiln Works
The electric kiln, housed within "Factory e", will replace conventional natural-gas-powered firing processes with a 100% electric, renewable-powered system. Once up and running, the new kiln is anticipated to cut Scope 1 carbon emissions by 75%, saving 4,700 tonnes of CO2 annually.
The project represents a £37m investment, with £4.3m secured through the UK Government's Industrial Energy Transformation Fund (IETF), which backs industrial fuel-switching and energy efficiency initiatives to aid decarbonisation efforts.
Impact on Production and Workforce
By eliminating natural gas entirely from the roof tile firing process, wienerberger bosses say Factory e is playing a pivotal role in the company's transition towards net-zero carbon emissions, while also safeguarding the long-term future of roof tile production at its Broomfleet facility. Factory e will take the place of a redundant production line at Broomfleet, with the existing manufacturing apparatus set to be entirely replaced as part of the transition to electric firing — all while maintaining continuous production.
Building work is already progressing on site, with the previous factory structure cleared and groundwork operations advancing. Essential machinery has started to arrive on location ahead of fitting.
Company Leadership Comments
Keith Barker, chief operating officer at wienerberger UK and Ireland, said: "The start of construction at Broomfleet represents a pivotal step in our journey to decarbonise heavy clay manufacturing. Factory e demonstrates how electrification can deliver substantial carbon emission reductions while maintaining product quality, operational resilience and long-term competitiveness."
"Alongside our hydrogen brick kiln project at Denton, it underlines our multi-technology approach to achieving net zero and our commitment to building for what's next," he added.
Mark Brook, operations director at wienerberger UK and Ireland, said: "Factory e will fundamentally change how roof tiles are made at Broomfleet. We are installing the first electric kiln of its kind for clay roof tiles, alongside modern automation and control technology that improves safety, efficiency and consistency."
"The same raw materials will be used, and extensive trials and testing give us confidence that product quality will remain unchanged. We are also investing significantly in our site workforce, creating development opportunities as we upskill teams to use the latest technology," Brook added.
Project Timeline
The Factory e project is scheduled for completion in 2027. As part of the changeover, production and engineering staff are being trained and equipped with new skills to operate and maintain the upgraded, more automated machinery.
