Visy Cullet Processing Plant
— Structural steel erection, cladding, electrical & mechanical installation for a large-scale glass recycling and cullet processing facility supporting high-volume manufacturing operations.
Visy Glass Operations (Australia) Pty Ltd
Industrial - Recycling / Glass Manufacturing
Subcontract (via Principal Contractor)
Build Run Repair (BRR)
Yatala, Queensland
2024 – 2025
Complete
Multi-level industrial processing facility exceeding 21 metres in height, incorporating advanced material handling and recycling systems.
Structural Steel Erection, Cladding, Electrical & Mechanical Installation
40 Tonnes Per Hour
Waste glass processing capacity
21+ Metres
Height of multi-level processing structure
2024–2025
Delivery program duration
Multiple Integrated Systems
Structural, conveying and processing infrastructure installed
Three Recycled Glass Streams
Amber, Green and Flint separation capability
— Project Overview
The Visy Cullet Processing Plant in Stapylton Queensland is a major component of Visy Glass Operations (Australia) Pty Ltd. ’s new Glass Recycling and Manufacturing Facility, developed to strengthen large-scale glass recovery and recycling operations in South-East Queensland.
Designed to process up to 40 tonnes of waste glass per hour, the facility separates recycled material into Amber, Green and Flint colour streams, creating a continuous supply of reusable material for glass production.
JKR Group was engaged by Build Run Repair (BRR) to deliver the structural steel erection, cladding, electrical and mechanical installation works for the processing facility. The scope included erection of the 21+ metre multi-level steel structure, installation of conveyor support systems, platforms, stairs and access walkways along with the installation and alignment of key mechanical equipment including hoppers, feeders, conveyors, rotary dryer systems, gas burners and associated transfer systems.
In addition, JKR also constructed the storage infrastructure, including full foundations (concrete slab and precast panels), the waste bunker and the fine glass storage building, providing complete structural and civil integration across the facility.
With multiple processing systems integrated across several levels, the project required precise coordination, sequencing and installation accuracy to ensure all structural and mechanical components operated efficiently within the broader recycling facility.
— Project Challenges
- Multi-Level Industrial Structure: The facility incorporated a complex steel structure exceeding 21 metres in height, requiring staged erection and accurate sequencing across multiple levels.
- Integration of Processing Equipment: Large-scale mechanical systems including conveyors, elevators, rotary dryers, feeders, and transfer systems required precise alignment and integration within confined structural areas.
- High-Volume Recycling Operations: The plant was designed to process up to 40 tonnes of waste glass per hour, meaning all structural and mechanical components needed to meet strict operational and performance requirements.
— Solution
JKR Group implemented a staged delivery methodology to ensure efficient coordination between structural steel erection and mechanical installation activities.
Structural works were sequenced to allow progressive installation of major processing equipment as the facility advanced through each construction stage. This approach minimised delays, improved access for installation teams and ensured accurate integration between all systems.
Key elements of the delivery included:
- Coordinated erection of the multi-level steel structure
- Installation and alignment of complex processing equipment
- Integration of conveyor and transfer systems throughout the facility
- Close collaboration with the principal contractor and equipment suppliers to maintain program continuity and installation accuracy
This coordinated approach enabled the project to progress safely and efficiently while meeting the operational requirements of the facility.
— Services Delivered
Structural Steel Erection
Erection of all prefabricated steelwork for the multi-level cullet processing facility exceeding 21 metres in height.
Processing Plant Infrastructure
Installation of structural frames, conveyor support structures, platforms, access walkways and stair systems throughout the facility.
Mechanical Installation
Installation and alignment of infeed hoppers, vibrating feeders, conveyors, elevators, rotary dryer systems, gas burners and transfer systems.
Material Handling Systems
Integration of conveying and processing equipment designed to support high-volume recycled glass handling operations.
Industrial Access Systems
Construction of maintenance and operational access areas to support long-term plant functionality and safety.
— Outcome
The Visy Cullet Processing Plant will provide a critical recycling and material recovery facility supporting ongoing glass manufacturing operations in South-East Queensland.
By delivering both the structural steel and mechanical installation scope, JKR Group contributed to the successful development of a high-capacity processing facility capable of supporting efficient recycled material handling and reuse.
The project highlights JKR’s capability to execute complex industrial processing infrastructure projects requiring detailed coordination across structural, mechanical and material handling systems.
