Ibstock invest in quality with major factory upgrade

Multi-million pound investment in Aldridge factory improves energy efficiency and brick quality

IBSTOCK have invested more than £12 million into their Aldridge factory, in Staffordshire, significantly improving energy efficiency and quality at the site.

As part of the investment, the company has upgraded the legacy technology in the facility. This includes installing brand-new, state-of-the-art dryers, which now include screen-controlled moisture monitoring. This helps minimize surplus heat wastage, without compromising on the final quality or durability of the bricks.

Similar upgrades have been made to the factory’s setting machine. By installing a new system, which is largely automated, the setter can now process 10,000 bricks an hour – double the previous machine’s capabilities and requiring just one operator, helping to improve workflow and efficiency on site.

Further efficiency gains have been made via the introduction of an automated unpacking process, overseen by a team of three, which replaces the previous by-hand system, which was both time-consuming and labour-intensive.

The investment has also enabled a total refurbishment of the kiln cars and upgrades to the kiln itself, driving vast improvements in energy performance at the site. Upon completion of the investment, Ibstock expect gas consumption at the Aldridge site to be reduced by 25%, which equates to a total carbon reduction of 19%.

However, the investment has not only allowed the company to make significant sustainability enhancements across the factory, but also to drive real improvements to final product quality.

The Aldridge site produces a broad and unique product range with rusticated finishes that are used widely on housing estates in the West Midlands and surrounding regions. Thanks to the upgrades to the site’s dryers and setting technology, Ibstock have been able to further strengthen the quality of the bricks, improving production yield by 10%. 

Jason Grimston, factory manager at Aldridge, said: ‘As factory manager, it has been fantastic to see the impact the investment is having on our operations here at Aldridge…the funding has propelled the factory into a new era, where our 37-strong on-site team are now able to maximize their efficiency by utilizing some truly state-of-the-art, semi-autonomous technology.

‘At full demand, the factory will be able to produce up to 30 million bricks per year – ensuring we can guarantee a consistent supply to merchants and their end customers. Our commitment, however, doesn’t end at quantity; it’s about quality and sustainability, too. By upgrading the technology we’re using to manufacture our bricks, we’re able to ensure real consistency of quality for each and every brick that leaves the kiln.

‘Indeed, with improved processes, we’re not just meeting standards – we’re setting new benchmarks for repeatability, consistency, and aesthetic appeal. This investment is future-proofing Aldridge to ensure we remain best placed to meet changing customer demand and build a future where innovation and sustainability go hand in hand.’