Brickset in Billund!

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Unfortunately our review of 76057 Spider-Man: Web Warriors Ultimate Bridge Battle is not quite ready yet so instead we are going to take a trip inside LEGO headquarters where the set was designed and perhaps manufactured.

Huw is currently representing Brickset at a media event in Billund and will be posting his full report in the next couple of weeks. Today he has been exploring the Kornmarken factory and the LEGO Ideas House. Photography is not usually permitted inside the factory but representatives of several LEGO websites have been allowed to take photos to share with readers, which you will find after the break...

Kornmarken Factory

ABS granulate waiting to be used:

Injection moulds in a storage area:

Moulding machines on the factory floor:

A moulding machine with granulate taken in at one end (left) and LEGO pieces dispensed at the other (right):

Technic bushes being dispensed from a moulding machine:

A robot collects a full box of parts to be taken away for storage:

Waste pieces which will be re-used:

Racks of LEGO pieces in storage:

A robot delivering more pieces to be stored:

From here these pieces will be transported to factories in other countries where the sets are packed and shipped out for sale across the world.


LEGO Idea House

Some sets on display in the LEGO Idea House:

More recent sets are also exhibited:

James Burns from Jedi News in the vault, which contains almost every set ever made:

Tim Johnson (Caperberry) from NEW ELEMENTARY poses with some Minitalia sets from the early 1970s:

The shelves are packed with sets from all eras. Here are some from the late 1970s:


Huw will be able to provide much more information on his return so keep an eye on the homepage for a full report.

Also look out for our review of 76057 Spider-Man: Web Warriors Ultimate Bridge Battle which will be posted tomorrow.

35 comments on this article

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By in United Kingdom,

Ah, the memories! I want to go back!
Can't wait to read Huw's full report.

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By in United States,

Very cool! Wish I could go there.

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By in United States,

That waste though...

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By in United States,

^For a factory of that size, that much waste is to be expected!

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By in Poland,

Fine, fine. Now, on with The Bridge Battle! ;-)

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By in United States,

I hope to one day visit the Lego vault!

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By in Canada,

They should let each visitor have one set from the vault. Now that would be motivation to go.

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By in United States,

Love seeing what's behind the curtain! Thanks for the great pics!

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By in United States,

Racks of LEGO pieces in storage... mmm...

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By in Australia,

That waste is extremely minimal compared to the amount they produce.

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By in United States,

Wait... why are they waste? Were there manufacturing errors? *panicky*

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By in United Kingdom,

The picture of the pieces in storage looks like something out of the X files!

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By in Poland,

The Vault... nearly Every Lego Set ever made... So that's how heaven looks like...

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By in United States,

Ah.....I so want to go back!

Some of the waste is generated when they change molds on the machines, especially when they change colours. They have a tight control on those. They also told us everything gets recycled.

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By in United Kingdom,

I would find it impossible to resist digging my hands into that box of yellow technic bushes and scrunching them while grinning like a goon

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By in Australia,

That truely is a magnificent place! I wish I was there

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By in Australia,

That vault.... *drools*

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By in United Kingdom,

It's really interesting to get the 'behind the curtain' pics like this. I sometimes catch a How It's Made and it's always interesting to see what actually goes on to manufacture the product we all know so well. Imagine the cost of all the injection moulds! I hope I will be able to get onto an inside tour some time in the coming years to get the full experience! I'd be interested to see some of the sets before my time in the flesh too - Fabuland seems to have a cult following. I also wonder if there's a Chrome C-3PO in the vault...

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By in United States,

Any chance you guys will get to visit one of the factories where they make the sets? I would love to see the manufacturing processes. I am a quality engineer by trade for heavy equipment.

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By in United States,

Would love to hold the Galaxy Explorer, sealed, one more time in my life, just to be able to relive that Christmas once again.

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By in United States,

My dream is to visit that Lego vault! it would be such an amazing experience to see every set ever made...

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By in United States,

Wow, it's like I saw all this stuff just last week...oh wait, I did! We on the Inside Tour couldn't take photos, so I'm glad these press entities like Brickset are able to document the areas I thought were going to have to be relegated to memory.

Fun fact: touching those pieces fresh out of the injection molding machines is considered a way to contaminate them, since they are still cooling and Lego is very strict on keeping the pieces pristine prior to packaging. On the tour, the guy in charge of the factory picked up a Technic beam piece from the machine, and after showing it to us, promptly crushed it in his hand and threw it in the box with all the other soon-to-be recycled pieces.

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By in Australia,

I wish the flights from AU weren't so expensive. Maybe in a few years, after I have done BW Chicago.

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By in Serbia,

@EvilTwin - When I visited the factory in 2014, they told us not to touch any of the parts coming out of the molding machines because any human contact is considered contamination and the whole batch would have to be destroyed.

It's funny how when you block the pathway of one of the robots that collect parts in the molding room he starts to beep impatiently :)

The storage facility is incredibly impressive - it's huge, and normally it's completely dark because robots don't need light to operate. There is a length of red cord running around the perimeter and touching it (another thing we were told not to do under any circumstances) causes the whole place to shut down immediately.

There are few human workers, almost everything is automated. Humans mainly perform monitoring/control and cleaning duties, robots do the rest.

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By in South Africa,

Thank you guys. I wish I had the chance to join one day. The vault is amazing!

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By in United Kingdom,

Ahhhh, that vault is amazing. If I was a member of Ocean's 11 I'd make that the next target!! ;-)

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By in Italy,

Does the vault have the 1979 hospital, the 1996 holiday village or the 1375 wrestling scene?

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By in Australia,

Just awesome !

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By in Croatia,

This media event likes the Inside Tour - for significantly less money I wish I were a LEGO-journalist.

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By in Australia,

#Jealous

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By in United States,

Thank you Brickset for posting articles such as this! Unfortunately this is as close as I will ever get to going on an Inside Tour. The Ideas room w/the Galaxy Explorer and Fabuland sets almost bring a happy nostalgic tear to my eyes.

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By in United States,

I'd love to go to the vault, just to see the BIONICLE sets.

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By in United Kingdom,

I wonder what sets they are missing from the Vault!?

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By in United Kingdom,

***INTENSE JEALOUSY INTENSIFIES***

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By in United Kingdom,


@ Sammael - is this the start of a robot dystopia, the only humans in the plant just do the cleaning??

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