1000 sustainable houses per year – How Kōzōwood plans to increase its production capacity

2024/08/07   |   Esposende   |   Portugal

By combining tradition, modern architecture and technological innovation, Kōzōwood is transforming sustainable housing construction in Portugal and is raising the bar for the industry higher than ever before. The name Kōzōwood is a portmanteau of the Japanese word Kōzō, meaning "structures," and wood.

New ideas for timber construction

Kōzōwood is the result of a collaboration between the current CEO Nuno Carvalho do Vale and his wife Isabel Afonso, the creators of the Ooty brand, and José Cardoso Botelho, CEO of Vanguard Properties, one of the country's most successful property developers.
This joint venture has already completed a wide range of projects, most of which are focused on high-quality residential construction. The company's developments in Comporta, southern Portugal, are particularly noteworthy. The two brands Kōzōwood and Ooty demonstrate the company's innovative approach, which focuses on efficiency, customer relationships and a high level of dedication to sustainability and quality. Kōzōwood is a pioneer in the use of wood as a key architectural element and is a strong proponent of the environmental and economic benefits that this building material offers.The company's commitment to sustainability and forest management is demonstrated by its PEFC (Programme for the Endorsement of Forest Certification) and FSC (Forest Stewardship Council) certifications. These certifications mean that the company ensures that every piece of wood they use comes from a sustainable source. Every project is planned with the environment in mind, with sustainability being at the heart of every single phase of construction.

Strong expansion thanks to investing in state-of-the-art technology

In order to expand production, Kōzōwood invested in the expansion of its two core areas: The production of timber frame elements and cross-laminated timber (CLT). This laid the foundation for further company growth in the long-term. Early on in its history, the company began using a WEINMANN production line for the prefabrication of timber construction elements. The production line was put into operation at the end of 2022 and now enables the company to manufacture 250 to 300 houses per year. To expand production further, the company also purchased a CLT line from System TM and Kallesoe, companies which are also part of the HOMAG Group. The production lines used by Kōzōwood enable the company to achieve a level of efficiency, quality and customer focus that is unrivaled in Southern Europe. To reduce the negative impact of the shortage of skilled workers, the company has also invested in internal training and international consulting services, which encompass employees in both the production and assembly departments. Kōzōwood currently employs around 100 people and plans to increase this figure by an additional 150 in the near future. By 2025, the company aims to be producing three houses per day, thus making its mark on both the national and international markets. To achieve this ambitious goal, investing in the right technology is key: Element production with WEINMANN machines begins with cutting and processing beams using the BEAMTEQ carpentry machine. The finished beams are then transported to the wall line or the roof and ceiling line. In the next step, the beams for wall production are precisely positioned on the BUILDTEQ assembly tables and connected. Using vacuum lifters, the sheathing materials are ergonomically positioned on the frame works and then secured using a WALLTEQ multifunction bridge. Next, the elements are turned automatically to start the blow-in process for insulation materials such as cellulose or wood fiber. This process is CNC-controlled by the WALLTEQ M-300.  The insulated elements are then sheathed and secured. The components are transported onward to a wall slot, where additional tasks such as window installation or facade processing are carried out. In keeping with Kōzōwood's motto, the production of closed and insulated elements promotes the sustainability and ecology of timber construction and simultaneously meets the high level of demand for long-lasting insulation and sound insulation. The technology used in the production lines enables Kōzōwood to build custom houses quickly and efficiently, while achieving an extraordinary level of ergonomics and productivity for its employees. In addition, prefabricating the elements in the factory drastically reduces the construction time required at the construction site.

Kōzōwood as a case study 

With impressive production facilities, a proactive attitude and qualified employees, the company has managed to grow rapidly and become a key player in the market. Kōzōwood is not only setting new standards for the Portuguese timber construction industry, but is also raising the bar for innovation and sustainability. The company pledges that every one of its projects will contribute to a greener and better future.