‘We are investing significantly in our site workforce, creating development opportunities as we upskill teams’
The world’s first fully electric tunnel kiln for the manufacture of clay roof tiles is being built at Broomfleet by wienerberger UK & Ireland(Image: wienerberger UK & Ireland)
Bosses at an East Yorkshire roof tile maker have hailed a major milestone as work gets under way on a world-first kiln in a multimillion-pound investment.
Wall, roof and landscaping specialist wienerberger UK & Ireland has started construction on the world’s first fully electric tunnel kiln which will be used to manufacture clay roof tiles at its Broomfleet base in East Yorkshire. The company, which also has operations at Killingholme, said the move marks a huge milestone in its long-term decarbonisation strategy and its ambition to transform heavy clay manufacturing.
The electric kiln in “Factory e” will replace the conventional natural-gas-powered firing processes with a 100% electric, renewable-powered system. Once operational, the new kiln is expected to reduce Scope 1 carbon emissions by 75%, saving 4,700 tonnes of CO₂ per year.
The project marks a £37m investment, with £4.3m funded through the UK Government’s Industrial Energy Transformation Fund (IETF), which supports industrial fuel-switching and energy efficiency projects to help decarbonise.
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By removing natural gas entirely from the roof tile firing process, wienerberger bosses say Factory e is playing a critical role in its switch to net-zero carbon emissions. It will also strengthen the long-term future of roof tile production at Broomfleet.
Factory e will replace a disused factory line at Broomfleet, and the old manufacturing equipment will undergo complete replacement in the move to electric firing – and it will be delivered without interrupting ongoing production. Construction activity is now under way on site, with the former factory building cleared and civil engineering works in progress. Key equipment has begun arriving on site in preparation for installation.
Keith Barker, chief operating officer at wienerberger UK & 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.”
Mark Brook, operations director at wienerberger UK & Ireland, added: “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.”
The Factory e project is planned to be completed in 2027. As part of the transition, production and engineering teams are being trained and upskilled to operate and maintain the new, more automated equipment.
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