EGGER Wood Products
Highly Automated Wood Manufacturing Facility.
EGGER is a family-owned, Austrian-based wood manufacturing company that produces panel products. These products are used in a variety of manufacturing items, including laminate flooring, cabinetry, residential, and commercial furniture, along with casework. The company knew it was time to expand its facilities to the U.S. and selected Gray to partner on its 20th manufacturing operation worldwide.
- LocationLexington, NC
- Square Footage859,000 s.f.
- Operational25 months
The highly automated facility produces panel products used in a variety of manufacturing items and includes a fully integrated 3D model along with laminated wood joist glulams shipped from Europe. Construction of the new facility allows EGGER greater flexibility to provide its North American customer base with an American-made product through more local supply chains with shorter lead times. The facility has brought an estimated 770 new jobs to the region.
Carsten Ritterbach, plant manager, Commercial Services, describes this facility as the “most modern plant in the world” for the type of product it manufactures. The Gray team placed a strong emphasis on providing flexible, innovative plant design and implementing safe practices.
“Gray and EGGER partnered with full collaboration on all aspects of the project including schedule, cost, and design,” said John Slone, director, operations, distribution, & commercial with Gray. We worked with EGGER and not for them. Both companies joined to essentially become one team, which developed a high level of trust among everyone.”
Production automation was facilitated by the latest Industry 4.0 technologies and state-of-the-art production equipment and technology—including 85,000 s.f. of AS/RS—while Gray collaboratively developed a project-wide safety program with OSHA advisors for the 1,150 workers on site.
As a result, Engineering News-Record recognized the EGGER plant as the Southeast region’s Best Project in the manufacturing category and awarded it for Excellence in Safety.
Charting New Territory
The Beginning of a Bright Future
Sharing Our Success
Egger’s North Carolina manufacturing facility wins Engineering News-Record awards for Project of the Year and Excellence in Safety.
EGGER Chooses Gray for Phase II
After the completion of the initial project, EGGER again selected Gray for a Phase II on the same campus—constructing a recycling facility to process waste wood from on-site operations and community recycling centers for use in new EGGER products.
The new recycling processes will complement the manufacturing facility’s output by sustainably reforming and redirecting materials back to production lines. Beyond the immediate benefits of upcycling waste material, this new on-site capability provides an opportunity for EGGER to reduce its carbon footprint while also implementing vertical integration in its production processes for greater supply chain predictability.
Finding creative ways to get more out of materials is not only sound investment, but in keeping with EGGER’S philosophy of taking ecological, economic and social responsibility for the role it plays in communities around the globe.
Process & Packaging Systems Engineering
Automation & Controls
Custom equipment Ovens & cookers Process skids Batching equipment Clean-in-place systems Bioreactors Extruders Distributed products Mixers & blenders
- ENR Southeast 2020 Best Project Award
EGGER Wood Products received Engineering News-Records’ 2020 Best Project award in the Southeast region’s manufacturing category for its Lexington, N.C. facility. ENR granted the award due to EGGER’s commitment to build the most modern manufacturing facility possible.
- ENR Southeast 2020 Excellence in Safety Award
EGGER Wood Products received Engineering News-Record’s 2020 Excellence in Safety award in the Southeast region for its Lexington, N.C., manufacturing facility. Gray Safety Services developed a comprehensive program for the project in collaboration with the North Carolina Department of Labor and on-site OSHA advisors.
Gray is a fully integrated global service provider specializing in engineering, design, construction, digital, equipment manufacturing, and real estate services.