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.

  • Location
    Lexington, NC
  • Square Footage
    859,000 s.f.
  • Operational
    25 months
EGGER Wood Products
Lexington, NC
859,000 s.f.
25 months
"EGGER is a fantastic company, and this project is a prime example of the excellence that can be produced through an effective partnership. We are proud to be a part of this great facility that will continue to produce quality products for decades to come."
Brett Goode, Executive Vice President, Food & Beverage Market

Gray

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.

Gallery

Charting New Territory

EGGER invests in company's first U.S. operation.
Learn More

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.

See What Makes Egger Special

EGGER Chooses Gray for Phase II

New Recycling Facility Turns Waste into Work.

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 as well as overheads by cutting out the transportation and outside labor costs typically associated with recycling.

 

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.

Explore Services

  • Process & Packaging Systems Engineering

    Civil/Building Engineering

    Mechanical/Electrical Engineering

  • Architecture

    BIM/VDC

    Sustainable Design

  • Pre-Construction

    Facility

    Equipment

  • Automation & Controls

    Production-First IT

    MES/MIS

    IoT/Data

  • Custom equipment Ovens & cookers
    Process skids Batching equipment
    Clean-in-place systems Bioreactors
    Extruders Distributed products
    Mixers & blenders
  • Feasibility Studies

    Pre-Construction

    Incentive Coordination

    Land Acquisition

    Construction Financing

    Build-to-Suit/Sale Leaseback

  • Master Planning

    Front-end Services

    Strategy Consulting

"At EGGER, where we have a deep respect for the natural resource of wood and are committed to sustainable use of wood, we believe this historic tradition is an appropriate way to mark an important milestone in construction of our Lexington manufacturing facility."
Karl Grasser, Project Manager for Finance/Administration

EGGER

About Gray

Gray is a fully integrated global service provider specializing in engineering, design, construction, digital, equipment manufacturing, and real estate services.