Kalamia Mill: Wilmar Sugar delivers new $12m stack in Burdekin

A high-tech demolition robot has played a key role in the transformation of the Burdekin skyline. SEE THE BEFORE AND AFTER.

A high-tech demolition robot has played a key role in the transformation of the Burdekin skyline.

Wilmar Sugar and Renewables’ said the Brokk robot had helped remove the two 50-year-old concrete stacks before the installation of a new $12m 72-metre boiler stack at its Kalamia Mill – all completed during a single, 20-week maintenance season.

Senior Project Engineer Fabian Sataro said the stack-replacement project was Wilmar’s biggest capital job at its four Burdekin mills this year.

“We knew it was a big undertaking to demolish two end-of-life stacks and erect a new one in a single maintenance season.”

Key players on the Kalamia Mill stack replacement witness the final section being lifted into place. Pictured, from left, are Kalamia Mill Work Coordinator Michael Gianni, Kalamia Mill Operations Coordinator Raymond Goggi, EDMS Site Coordinator Jeff Drayton, Kalamia Mill Engineering Superintendent Vito Giarrusso, EDMS Construction Project Manager Jamie Hervey and Wilmar Sugar and Renewables Senior Project Engineer Fabian Sataro. Picture: Cameron Laird

Mr Sataro said it was engineering-design team and principal contractor EDMS Australia formulated the idea of using the robot, “as well as some solutions to optimise the new stack design”.

“The robot removed the need for personnel to be working at heights, which aligned with our safety requirements,” he said.

“It could also work around the clock, even in wet weather and high winds, so it could get the job done faster and safer than people working from a suspended work platform.”

The two concrete stacks (pictured) that once towered over Kalamia Mill for 50 years have been replaced by a single steel stack. With the 2025 crushing season starting this week, it means local residents will now see steam rising from a single stack at Kalamia Mill instead of the familiar two. Picture: Supplied

The two concrete stacks that once towered over Kalamia Mill for 50 years have been replaced by a single steel stack (pictured). With the 2025 crushing season starting this week, it means local residents will now see steam rising from a single stack at Kalamia Mill instead of the familiar two. Picture: Supplied

The new steel stack was fabricated at EDMS’s Townsville workshop and erected in five sections at the mill with local subcontractors GPB Construction and Lancini Consulting Engineers completing the civil works.

Demolition of the first concrete stack at Kalamia Mill involving a Brokk demolition robot began in late December 2024. Wilmar’s General Manager Engineering Istvan Torok said the project reflected the company’s commitment to safety, innovation, and regional investment. Picture: Supplied

Wilmar’s General Manager Engineering Istvan Torok said the project showed “what can be achieved through smart planning, strong partnerships, and a focus on safety and performance.”

The last of five sections of the $12 million, 72-metre boiler stack at Kalamia Mill was lifted into place in May, 2025. Picture: Cameron Laird

“We had initially planned to execute this project over two maintenance seasons, but we challenged that and came up with a much tighter execution plan that delivered significant cost savings, greater efficiencies and key safety benefits,” he said.

Fabricators join the final section on the $12 million, 72-metre boiler stack at Kalamia Mill. Picture: Cameron Laird

“This sort of innovative thinking and engineering excellence is critical to our ongoing success as a leading Australian producer of sugar and renewables.”

Originally published as Kalamia Mill: Wilmar Sugar delivers new $12m stack in Burdekin