GreenBricks: wienerberger launches Europe's "greenest" brick production plant in Uttendorf

• Strong collaboration between industry and research enables groundbreaking demonstration projects like GreenBricks
• After 24 months of reconstruction, Wienerberger officially launched its most sustainable brick production facility within the group on November 28, 2024, at its Uttendorf plant.
• Utilising the world's largest industrial electric kiln, the demonstration site achieves up to a 90% reduction in CO₂ emissions.

As a trailblazer in energy efficiency and CO₂ reduction, Wienerberger has established Europe’s most sustainable brick production facility at its Upper Austrian plant in Uttendorf. The traditional gas kiln for brick productiong was replaced with the first industrial electric one, powered by green electricity, including energy from an on-site PV system. This transition reduces the production’s CO₂ footprint by nearly 90%, equivalent to cutting approximately 7,340 tons of CO₂ emissions annually—comparable to 600 trips around the Earth by car each year.

Johann Marchner, Country Managing Director of Wienerberger Austria, remarked: 'With the successful commissioning of the electric kiln, we have achieved a true milestone for sustainable brick production. The comprehensive reconstruction demonstrates Wienerberger’s commitment to taking significant steps for climate protection while making long-term investments in Austria as a vital economic hub. My heartfelt thanks go to everyone who contributed to the successful realisation of the GreenBricks project—I am thrilled to celebrate the opening of our 'greenest' production site.'

Uttendorf as an International Flagship Facility

Owned by Wienerberger since 1987, the Uttendorf plant in Upper Austria has become a global demonstration site for testing pioneering technologies in live operations. In 2019, it became the first facility to implement an industrial high-temperature heat pump for drying processes.

Starting in spring 2022, as part of the NEFI project 'GreenBricks'—funded by the Austrian Climate and Energy Fund under the 'Vorzeigeregion Energie' initiative—the gradual replacement of the gas furnace for brick productiong with the first industrial electric kiln was undertaken in collaboration with the AIT Austrian Institute of Technology (AIT). Additionally, a new hall for sawdust preparation and three new heat pumps were installed. Automatic Guided Vehicles (AGVs) now transport the nearly climate-neutral bricks, replacing traditional kiln carts. The plant’s electrical infrastructure and much of the clay preparation process were also modernised.

Andreas Kugi, Scientific Director at AIT, stated: 'The successful realisation of the NEFI project ‘GreenBricks’ highlights how crucial close collaboration between industry and research, coupled with the adoption of new technologies, is for the future of production. Using innovative digital planning and simulation tools, we not only made brick production at Uttendorf more sustainable but also more efficient. These projects underline that digitalisation and virtual planning are key to decarbonisation and maintaining the competitiveness of industry.'

Strong Industry-Research Collaboration as the Foundation for Innovation

The longstanding partnership between AIT and Wienerberger Austria began in Uttendorf, where the EU project DryFiciency introduced the first successful industrial high-temperature heat pump for drying processes—a groundbreaking example of technological innovation.

The NEFI project 'GreenBricks' has deepened this partnership, elevating it to a new level. Uttendorf has been completely redesigned, modernised, and strategically oriented toward decarbonisation. A key milestone is the installation of the world’s largest industrial electric kiln for brick production, reshaping the energy needs of industrial processes sustainably.

Through the NEFI – New Energy for Industry network, research and practice are seamlessly integrated. The NEFI framework provides optimal conditions for testing and quickly implementing new technologies directly within companies.

Innovative Energy Concept for Wienerberger’s Uttendorf Plant

The reconstruction of the plant was meticulously planned using digital tools developed by experts at AIT’s Center for Energy. These tools simulated calculations around the new electric kiln and digitally optimised processes for climate protection. They also serve as digital twins in ongoing production, allowing adjustments to manufacturing conditions for bricks and their impact on operations to be accurately forecasted and implemented.

Heat pumps enhance the energy efficiency of drying processes by converting industrial waste heat from the tunnel dryer into usable energy and reintegrating it into production. 'Heat pumps are a viable alternative to conventional gas burners for many drying processes and can be implemented across various industries, including paper, food and beverages, textiles, and chemicals,' explained Tilman Barz, scientific coordinator of the GreenBricks project and Senior Scientist at AIT’s Center for Energy.

Electrifying Industrial Kilns: A Technology Leap for Decarbonisation

The electrification of previously gas-fired industrial kilns represents a significant technological leap, accompanied by various technical challenges and process-level adaptations. 'Using novel digital tools, innovative virtual planning methods, and detailed analyses of high-temperature heat processes up to 950°C, we established the groundwork for replacing traditional firing technology with a green electric kiln while maintaining capacity and quality,' Barz elaborated.

Currently, the plant is in the testing phase, with a production capacity of 270 tons of bricks per day being evaluated. Under the leadership of Plant Manager/ GreenBricks Project Manager Gerhard Pichler, 16 employees ensure smooth operations. Starting in 2025, Europe’s greenest brick production plant will enter regular operation.

Further information about the NEFI projectGreenBricks you will find here: GreenBricks- NEFI and GreenBricks in Uttendorf (in German).