Why do Legos come in separate bags?
LEGO puts its pieces in small baggies to make the job of packing a box cheaper and less error-prone. When LEGO wants to include elements in a set, they have to gather together all the elements necessary, and put them into something.
Lego takes quality and packaging very seriously and has developed a system of automated machines and scales to identify any missing componets. Lego weighs the bricks in each bag and box to ensure that the right components are present however they usually add a few random small pieces.
The tubes on the bottom interlock with the studs on top of other bricks. The studs get neatly wedged in between the tubes and the sides of every brick making them stick together firmly. The clutch power of LEGO® bricks has made it possible to create bigger and bigger sets without them falling apart.
Our baseplates are now wrapped in paper-based packaging. The new baseplate packaging replaces single-use plastic wrappers and will be phased in during 2022. Our paper-based baseplate packaging can be recycled in many of our markets.
The majority of brick today are packaged in self-contained, strapped cubes, which can be broken down into individual strapped packages for ease of handling on the jobsite.
Don't worry if there are some extra pieces left even though you closely followed the building instructions. LEGO TECHNIC sets can be built in more than one way, and you'll need the extra pieces to build the alternative model.
Gluing your bricks can make them change shape and we think it's way more fun to be able to take your sets apart and rebuild them into something new! You can use your LEGO pieces over and over again to build anything you want in limitless combinations.
That's equivalent to a mass of 432kg (950lbs). If you divide that by the mass of a single brick, which is 1.152g, then you get the grand total of bricks a single piece of Lego could support: 375,000. So, 375,000 bricks towering 3.5km (2.17 miles) high is what it would take to break a Lego brick.
The Lego manufacturing process starts with tiny granules of ABS, brought by the lorry-load to factories. Here, they're dumped into giant metal silos, then fed into molding machines where they're heated to 230˚C (450˚F). This melts the granules, producing a plastic goo which is automatically fed into Lego part molds.
From the silos, the plastic granules are fed down pipes to the moulding machines. Inside the moulding machines, the granules are superheated to a temperature of about 450 degrees Fahrenheit (230°C). This melted plastic goo is fed into moulds, little metal containers shaped like hollow LEGO bricks.
What manufacturing process is used for LEGO?
All of the basic Lego elements start out as plastic granules composed primarily of acrylonitrile butadiene styrene – material Lego is trying to get away from. A highly automated injection molding process turns these granules into recognizable bricks.
During the packaging process, bins open and close automatically, dropping precise numbers of bricks into each polypropylene bag. A machine weighs these bags to make sure their contents are correct. If a specific bag's weight is incorrect, an operator can replace that bag, rather than having to discard an entire set.