The Visy Glass Recycling and Manufacturing Facility at Stapylton, Queensland, is a major industrial development combining a glass recycling cullet plant, container glass manufacturing facility, and finished goods warehouse on a greenfield and brownfield site.

The facility, which represents the largest investment Visy has ever made, will recycle up to 200,000 tonnes of Queensland’s glass annually to produce 1 billion bottles per year.

Build Run Repair (BRR) was engaged as Principal Contractor, with power supplied via redundant 33kV utility feeders feeding an Intake Switching Substation (ISS), where voltage is stepped down to 11kV for reticulation throughout the new Yatala Glass Manufacturing Facility.

Nilsen’s scope comprised the complete civil, structural, mechanical, electrical, and communications detailed design for the Intake Switching Substation, switchrooms, and supporting infrastructure. This included preparation of drawings, specifications, engineering calculations, bills of materials, and all documentation required for design certification and approvals. Key design elements included earthing and lightning protection systems, transformer and switchgear integration, utility-compliant civil and electrical designs, and the supply and installation of 33kV and 11kV switchrooms.

The project incorporated major OEM-supplied equipment, including 33/11kV transformers with on-load tap changers, 11/0.433kV service transformers, and 33kV and 11kV switchgear. Nilsen also designed all ancillary systems required for a fully integrated facility, including DC battery chargers, protection and control distribution boards, metering panels, remote operation panels, fire detection and protection systems, and cable termination infrastructure.

Technical innovation was central to the project.

Nilsen developed integrated substation and switchroom solutions that optimised access, safety, maintainability, and operational reliability. Innovative engineering approaches were applied to cable management, earthing systems, equipment interfaces, and the coordination of multiple high-voltage assets within a constrained industrial environment.

Sustainability considerations were embedded throughout the design and delivery process. Efficient engineering minimised material use and optimised existing infrastructure interfaces where possible. Construction methodologies were selected to reduce environmental impact and site disturbance while supporting long-term asset performance and maintainability.

A rigorous quality assurance framework ensured compliance with all applicable standards, utility requirements, and client specifications. Detailed inspection and test plans, structured hold points, verification processes, and comprehensive documentation delivered a high-quality outcome and successful commissioning.

Project success was achieved through detailed planning, effective stakeholder engagement, and strong project management. Close coordination between designers, suppliers, contractors, and client representatives ensured the works were delivered safely, on time, and within budget while meeting Visy’s operational requirements.

Work Health and Safety was prioritised throughout, with robust risk assessments, Safe Work Method Statements (SWMS), permit systems, and strict control measures applied to high-risk activities. The project was completed with an excellent safety record and no injuries.

The project also provided valuable training and development opportunities for apprentices and junior personnel, reinforcing Nilsen’s commitment to workforce development and continuous improvement in the delivery of complex electrical infrastructure projects.

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