Elesa presents the new Gigafactory

Elesa is strengthening its production capacity with the new Gigafactory, a facility created through the expansion and transformation of the Monza Headquarters, designed to meet the growing global demand for components that meet high standards of quality and performance. Supported by an investment of €39 million (€34 million allocated to the building and high-tech production systems, and €5 million to the implementation of more specialised innovative automation), the new facility covers an area of approximately 10,000 m² dedicated to production and around 3,000 m² of office space, with new areas specifically designed to ensure the highest levels of comfort and wellbeing for employees.

The Gigafactory integrates advanced automation systems, digital technologies for process management and Industry 4.0 solutions with an organisational model that brings production, logistics, energy and services together within a single industrial ecosystem.
The Gigafactory translates one of Elesa’s distinctive principles, performing design, to an industrial scale: the ability to develop solutions that combine the efficiency and flexibility needed to adapt to the future evolution of processes, technologies and production volumes.

This long-term vision also encompasses sustainability, which from the outset has guided the design of the building towards an integrated system of construction and technological solutions aimed at reducing environmental impact throughout its entire life cycle. Materials with a high percentage of recycled content have been used, together with prefab solutions designed to facilitate future dismantling, recovery and recycling operations.

“The Gigafactory represents much more than an expansion of our production capacity: it demonstrates Elesa’s commitment to continuing to grow in the area where the company was founded and built its industrial identity, consolidating a Made in Italy model based on innovation, quality, reliability and customer service. At the same time, it helps strengthen our competitiveness in international markets. This project brings together technological innovation, sustainability and a focus on people – elements that have always guided the way we do business,” said Carlo Bertani, CEO of Elesa S.p.A.

A distinctive feature of the project is the Digital Twin, the three-dimensional digital replica of the building and its systems developed in a BIM environment (Building Information Modeling). From the earliest stages, it enabled the complexity of the project to be managed and the structures, systems and production infrastructure to be coordinated during the construction of the new facilities.

Today, the digital twin supports the management and ongoing development of the plant. Constantly updated, it monitors the systems in real time, maintains a record of maintenance and other interventions, anticipates potential issues and helps identify criticalities at an early stage, reducing plant downtime.

In terms of energy efficiency, the Gigafactory is equipped with a photovoltaic system with an expected annual output of approximately 740,000 kWh, helping to improve the overall efficiency of the facility.

The building envelope has been designed to combine energy efficiency, comfort and high-quality indoor environments through extensive use of natural light. In the offices, full-height glazing with solar-control glass and shading systems provides ample daylight while ensuring thermal insulation; in the production areas and communal spaces, skylights and openings help create welcoming and functional working environments.
These solutions contributed to achieving Energy Efficiency Class A4 (the highest rating on the Italian scale from G to A4), a particularly significant result for a manufacturing facility.

The inauguration of the new Gigafactory is scheduled for 19 September.

The event, named Gigaday, will be attended by the employees and their families, as well as the professionals and construction companies involved in the development of the project, representatives of the institutions that supported the company throughout its implementation, and some former employees.