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LEGO Bricks In The Making

[Music]

the lego brick is an old invention by

now the first plastic brick was molded

in 1949 since then thousands of new and

unique Lego elements have been developed

pick a Lego brick from a box today and

it will fit with any brick that was

molded decades ago this is the result of

great precision and commitment for more

than 50 years the LEGO Group has

factories across the world but how do

you produce hundreds of different types

of bricks with such precision and in a

wealth of colors every single day

[Music]

and how do the bricks find their way to

the right boxes this is the story about

how small pieces of plastic granulate

are transformed into creative places our

truck arrives with raw material at the

factory a truck like this holds up to 28

tons of plastic granulate the granulate

is blasted from the truck into tall

silos where it is stored different types

of plastic granulator used depending on

the function of each Lego element the

granulated spread down a labyrinth of

long pipes into the factory the pipes

lead to the heart of the Lego factory

the molding area

[Music]

I take injection molding machines

produce Lego elements 24 hours a day

seven days a week

first the raw granulate is mixed with

the dye bricks are currently produced in

over 50 different colors

the colored granulates is then led into

the molding machine within no time

the granulate is heated to between 230

and 310 degrees Celsius the plastic

melts into a texture much like

toothpaste with great force the paste is

then fed into the mold great forces must

be controlled during this process the

pressure can reach 29 thousand psi in

comparison a car's tire pressure is 29

to 43 psi in the mould the material is

cooled in a matter of seconds and out

comes a newborn Lego brick as we know it

[Music]

plastic wastes from the molding machines

it's ground and recycled straight away

each moles can make one shape of lego

elements at a time so make a different

shape of elements the molds must

therefore be replaced the unique molds

are part of the secret behind the

success of the LEGO Group in each

factory there's a department dedicated

to regular cleaning and maintenance of

the molds the molds are made with great

accuracy ensuring that all Lego bricks

always fit together perfectly the molds

are therefore handled with greatest care

each mold has a specific set of

instructions which among other things

cover pressure time and temperature

temperature tests and molding tests are

carried out to ensure the machine is

programmed to perfection at each

replacement of the molds samples are

sent to the Quality department which

measures such things as the durability

and precision of the element it is

ensured that the Lego element is perfect

AGV stands for automatic guided vehicle

robots like these were introduced into

the production as early as 1987 when the

books by the moulding machine is full

these intelligent helped us replace it

with a new empty box

the AGB then takes the full boxes to the

conveyor system

a unique barcode identifies the contents

of each box

the boxes are shaken to even out the

content ensuring it takes up as little

space as possible

now the lids can be closed this is where

the journey of the boxes ends for now

in high bay warehouses up to 37 meters

high the boxes are ready to be collected

when a specific lego element is required

the box is collected all registration

and glocalization is entirely automated

the boxes are then transported onwards

from here many elements are taken

directly to the packaging lines but not

these little guys that many figures must

first get their own unique expression a

machine can produce more than 7,000

torsos per hour over half a billion

minifigures are produced every year

making them one of the world's largest

populations

in the first part of the packaging

process counting machines ensure that

elements are put in small production

boxes one by one they're weighed and

measured to secure the right numbers in

each box the bricks to be included in

just one bag in a complete Lego set are

placed in rows of counting machines the

contents of each production box is then

automatically put in a plastic bag

[Applause]

the bags are dropped into open Lego

boxes along with the building

instructions and large special elements

the most efficient packaging lines pack

over 50,000 boxes every 24 hours

now the boxes are closed and sealed here

we have final Lego boxes as we know them

the Lego boxes are packed for shipping

and stacked onto pallets they are now

ready for a long journey first stop of

the journey is at one of the large

distribution centers

[Applause]

from here they are shipped to stores all

over the world

it is now up to children and adults to

explore the fun and creative building

experiences of the Lego set