Industry: Recycling & Resource Recovery
The Client
- Industry: Recycling & Resource Recovery
- Location: Melbourne’s West, Victoria
- Type of Facility: Industrial Recycling & Processing Plant
A Melbourne-based recycling facility using advanced processing technology to transform industrial and construction waste — including stormwater and drilling muds — into high-quality reusable resources such as sand and aggregates for the circular economy.
The Operational Challenge
In early 2024, the client planned a major upgrade to their facility to support increased processing capacity and the introduction of three new plants.
The scope was significant — a complete upgrade of the facility mains, installation of a new 800A main switchboard, three new distribution boards, and field wiring to dozens of three phase motors, pumps, valves, sensors, and other control devices.
Adding to the complexity, the client needed the works completed within a tight timeframe while continuing day-to-day operations. Any extended power outage would directly impact production, so the project required careful planning, coordination, and a temporary power solution to keep the site running throughout the transition.
Objectives
The client required:
- A complete upgrade of the facility mains
- Installation of a new 800A main switchboard
- Installation of three new distribution boards to service three new plants
- Field wiring to all motors, pumps, valves, sensors, and control devices
- Continuity of operations throughout the project
- Delivery within a tight project timeframe
- Full testing, commissioning, and ongoing maintenance support
Our Solution
CW managed the project end-to-end, delivering:
- Supply and connection of a temporary 800A generator to maintain plant operations while Powercor mains were being established
- Complete facility mains upgrade
- Installation of a new 800A main switchboard
- Installation of three new distribution boards servicing the three new plants
- Field wiring to dozens of three phase motors, pumps, valves, sensors, and other control devices
- Full testing and commissioning of all new electrical infrastructure
- Coordinated cutover from temporary generator power to permanent Powercor supply with minimal disruption
Throughout the project, works were carefully sequenced and scheduled to allow the client to continue operating while the upgrade progressed in the background.
The Result
The facility was successfully upgraded on time, with the new 800A main switchboard, distribution boards, and field wiring fully tested, commissioned, and handed over.
The site has now been operating reliably for over two years, with CW continuing to provide ongoing electrical maintenance and support. The client benefits from a robust, well-documented electrical system built to support their growing recycling and resource recovery operations.
Key Client Benefits
- Turnkey project delivery from mains upgrade through to commissioning
- Continuity of operations maintained via temporary 800A generator supply
- New 800A main switchboard and three distribution boards supporting plant expansion
- Comprehensive field wiring to all process equipment
- Project delivered within a tight timeframe with minimal disruption
- Reliable performance — over two years of stable operation since commissioning
- Ongoing maintenance partnership providing long-term electrical support
