Nation’s Largest Brick-making Plant Opens
WIN Energy REMC powers new “green” factory in west-central Indiana
A $58 million factory that can produce 120,000,000 bricks per year, enough to build 8,300 all-brick homes, was not a typical project for economic development leaders in Terre Haute, Indiana.
Even so, when Boral Bricks Inc. laid out plans for a 295,000-square-foot manufacturing plant, with an enormous kiln operating at 2,000 degrees Fahrenheit, 530 feet long and 33 feet wide, making it the largest in the U.S., local officials quickly stepped up and met the challenge. The facility opened in March 2008 and will create 50 full-time jobs.
WIN Energy assisted in site location and worked closely with the local economic development organization and the company to meet Boral’s power needs.
“They selected WIN Energy because our proposal best met their needs. Plus, we provided them with substantial engineering support. Our engineers, with the assistance of Hoosier Energy, worked closely with theirs on the project,” said Tom Gregory, director of finance and administration for WIN Energy.
WIN installed the electrical distribution structure for the huge plant, about 1.5 miles of 3-phase power line and three 2,500 KVA transformers, at no cost.
“WIN Energy has been an outstanding partner in this and other projects to create new jobs and capital investment in the community”, said Steve Witt, president of the Terre Haute Economic Development Corp.
“They’ve provided reliable electrical power, making sure the company’s needs are met. Boral is a significant user of electrical power,” Witt noted.
Proximity to the high-grade clay necessary for brick making was one reason Boral chose the Terre Haute site, and the location places the factory close to customers in the company’s Midwest markets. Another factor was Boral could tap into the methane gas produced by a nearby landfill.
Using the landfill methane helps Boral cut costs and meets the company’s commitment to be environmentally friendly – the plant is capable of running on 100 percent methane. WIN Energy also provides the electricity to power the methane procurement station.
“They worked diligently with us to find a site for the substation. They ran a 3-phase dedicated line and we have single-source primary metering,” said Terry Schimmel, vice president of technical services for Boral Bricks.
Besides using the landfill methane, Boral reclaims shale from a coal strip-mining operation nearby to use in the manufacturing process. The brick factory uses high-tech machines and incorporates other measures to make the operation extremely energy efficient, producing nearly zero waste. The facility is believed to be the first manufacturing plant in Vigo County that has been certified LEED (Leadership in Energy and Environmental Design) by the U.S. Green Building Council.