The molding machines

Everything is recycled in the factory. The plastic granulate itself is a by-product from diesel, and whatever is discarded in the manufacturing process gets recycled. The leftover parts from the mold—the plastic that fills the channels that take the hot plastic into the piece negative—fall down the machine, gets ground up, and put back into the production cycle. Any other waste, like faulty pieces or the transparent plastic used to clean the inner tubes when they need to change the production color of a molding machine, are also ground up and sold to other companies for the production of other things, like pipes and even heating oil.

The machines produce more than two million pieces per hour, churning incessantly into color- and bar-coded boxes. I looked around and I couldn't see many people. A woman was in one of those endless aisles looking at a few molding machines with big "QT" signs on them. She was in charge of quality testing, making sure that the production was going perfectly.

At one point I was taking photos of a box of full of yellow bricks, and suddenly the machine stopped working. Fearing I had done something wrong, I saw a big wonky box coming from the distance, some kind of weird transport with strange sensors on the top, straight from a moisture farm on Tatooine or a spice mine in Dune. I stepped back, instantly realizing it was one of the many factory robots.

This transport bot was answering the call of the central mainframes, the brains of the Lego body that control every aspect of the process at all times. The mainframes had stopped the production of the machine, following the signal of the sensor next to the box and sending the signal to the robot, alerting it that it had to harvest the crop of bricks. The robots travel down the aisles autonomously, picking up boxes and leaving empty ones so production can be resumed.