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Alloy Fabweld: Pioneering Sustainable Manufacturing at Scale

At Alloy Fabweld, we take immense pride in being a leading UK manufacturer specialising in metal architecture for tall building structures, with a primary focus on modular construction. With a rich history of consistently delivering high-quality projects on time and within budget, we recognise that our commitment to sustainability is paramount in all our operations.

Our Sustainable Oasis: Gosfield, Essex

Our main production facility is nestled in the picturesque surroundings of Gosfield, Essex. Here, the site adjacent to our expansive production facilities has been developed into one of the UK's first carbon-neutral off-grid large-scale manufacturing facilities, allowing us to run our operations at the site on renewable energy, setting a standard for the industry.

Harvesting the Power of the Sun: Solar Farm

Our sustainability journey begins with our energy source - an expansive solar farm adjacent to our facility. This remarkable solar farm was developed on low-productivity agricultural land and boasts an array of 44,976 solar panels. These panels are strategically positioned to allow animal grazing, support plant life, and preserve natural habitats.

Each panel has the impressive capacity to produce up to 11.47MWp of clean renewable electricity annually, equivalent to powering approximately 3,545 homes. Moreover, we are proud to say that all of our electrical consumption in our engineering and manufacturing operations at our Gosfield facility is met through this green energy supply. This choice ensures that we operate as environmentally efficiently as possible, and it will enable us to save a remarkable 165,000 tonnes of carbon over the next 25 years.

Harnessing the Power of Waste: Anaerobic Digester

But our commitment to green energy doesn't stop with solar power. In addition solar farm, there is an on-site anaerobic digestion plant. This innovative facility efficiently converts organic waste into biogas, a clean and renewable energy source. The biogas is then used to generate electricity and heat, contributing towards powering our energy requirements.

The organic matter that fuels this process, such as maize, grass, and whole-crop cereal, is primarily sourced from local farms. However, the environmental benefits extend beyond energy production. The anaerobic digestion process leaves behind 3,000 tonnes of organic fertiliser, which we thoughtfully spread onto local farmland. This practice not only enriches the soil but also replaces fossil fuel-derived fertilisers, saving five tonnes of carbon for every ton of Nitrogen.

In essence, the Anaerobic Digester facility at the Gosfield site isn't just a power generator; it's a catalyst for sustainability. It provides power for site's production facilities at night and fulfills some of the on-site factory's heat requirements. Any surplus electricity the site generates flows back into the grid, benefiting the local community.

A Commitment to Continuous Improvement

At Alloy Fabweld, sustainability isn't a static achievement; it's an ongoing journey. We're dedicated to continuous research and development, tirelessly seeking innovative ways to make our products even more sustainable. This commitment is reflected in our use of the DFMA (Design for Manufacturing and Assembly) methodology, which not only reduces waste but also enhances efficiency in production.

Empowering Clients in Sustainability

Our commitment to sustainability extends beyond our operations. We firmly believe in empowering our clients to reduce their environmental footprint. With our range of modular construction solutions, we enable businesses to minimise energy consumption and cut carbon emissions. Our projects, which range from £3-£10 million and include iconic structures like the K1 Floating Pavilions in Battersea and the Embassy Gardens development in Nine Elms, showcase our expertise and dedication to sustainable construction.

Building a Greener Future Together

Our journey toward sustainability doesn't stop at reducing carbon emissions and increasing energy efficiency. It's about improving air quality, promoting biodiversity, and fostering positive community relations. By choosing Alloy Fabweld as your sustainable manufacturing partner, you're not just making a business decision; you're contributing to the creation of a more sustainable future.

In conclusion, Alloy Fabweld is not just a manufacturer; we're visionary leaders in sustainable manufacturing. Our dedication to green energy, innovative practices, and commitment to empowering others in their sustainability journey makes us an outstanding choice for businesses looking to build a greener, more sustainable future. Together, we can make a difference, one sustainable project at a time.

[Watch the video] To learn more about our commitment to sustainability and the remarkable impact of our green initiatives.

Choosing Alloy Fabweld means choosing sustainability, innovation, and a brighter future for all.


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