Twofold Increase in Pistachio Storage Capacity for APP
Australian Pioneer Pistachio Company (APPC) is one of Australia’s leading pistachio producers. Following ammjohn’s successful completion of a long-term facility masterplan to guide expansion through to 2050, APPC progressed Stage 1 of its defined growth pathway to support forecast 2026 harvest volumes.
The masterplan identified increased hulled pistachio storage capacity as the critical first investment required to unlock future processing and throughput growth. This requirement was driven by a step change in forecast volumes, resulting from significant areas of new orchards planted in previous years now reaching maturity and entering full production. Compounding this uplift was the cyclical nature of pistachio production, with the upcoming season forecast to be a biannual “on year,” generating substantially higher yields. Together, these factors created a near-term surge in harvest volumes that exceeded existing storage capacity and necessitated immediate infrastructure expansion.
This project represents the first capital delivery phase of the structured expansion plan — translating strategic planning outcomes into tangible infrastructure that enables near-term growth while establishing the foundation for subsequent development stages.
The brief
The project’s primary objective was to deliver a two-fold increase in on-site storage capacity (2000 tons) ahead of the 2026 harvest season within a tight timeframe. The solution needed to be fully integrated into an operating brownfield processing facility, requiring careful management of plant interfaces, tie-ins to existing materials handling systems, and coordination around live operations.
The project
The project comprised the detailed design, procurement, construction, and commissioning of four new 500-tonne pistachio storage silos, increasing total on-site hulled pistachio capacity by more than 2,000 tonnes ahead of the 2026 harvest. Delivered within a brownfield environment, the works were carefully sequenced to integrate with existing operations while maintaining production continuity, safety performance, and readiness for peak harvest intake.
Beyond the new silos the scope included the installation of new infeed conveyors, transfer points, and dryer fans to manage increased throughput. Each silo was equipped with internal reclaim sweep systems to ensure efficient discharge and operational reliability. The works also incorporated access platforms and associated safety infrastructure, along with enabling civil works and stormwater systems to support the expanded footprint. Electrical systems, controls architecture, programming, and full commissioning were delivered to ensure complete integration with the existing processing facility.
Construction staging, tie-ins, and commissioning activities were tightly coordinated to minimise disruption to harvest preparations and meet critical seasonal deadlines. The project also provided a practical validation of procurement strategies, international supplier coordination, and contractor performance to inform and de-risk subsequent expansion stages identified in the long-term masterplan.
Our scope
Ammjohn’s scope comprised:
- Project engineering across the full project delivery lifecycle (concept to handover)
- Cost, schedule, and risk management
- Commercial & Contractual negotiations with on-going administration
- Market-led procurement and tender evaluation
- Confirmation of user requirements and development site-wide technical standards
- Coordination of design, procurement, construction, and commissioning
- Structured stakeholder engagement and reporting
We maintained an appropriate level of on-site presence throughout the installation phase and were instrumental in driving the project through to a successful commissioning.
Outcome
Ammjohn delivered the following outcomes:
- Four new silo assets delivered, commissioned & online within the approved capital budget
- Completion achieved ahead of critical harvest deadlines
- Seamless integration with existing materials handling & processing infrastructure
- Minimal disruption to ongoing site operations and maintained safety performance
- Delivery models and key vendors validated to support future expansion stages, including effective management of international supplier procurement, manufacturing oversight, and complex freight and logistics coordination
- Infrastructure installed in alignment with the long-term masterplan roadmap, establishing a scalable foundation for subsequent upgrades
All project documentation was completed and handed over in structured formats to support operations, maintenance, and future works.
Key attributes demonstrated
- End-to-End Project Support & Integration
Seamless transition from strategic planning into detailed design, construction/commissioning & handover to operations – ensuring alignment with the broader 2050 growth roadmap.
- Structured Project Controls
Application of disciplined cost management, programme tracking, and change control processes to successfully deliver four silo assets within the approved capital budget.
- Integrated Multi-Disciplinary Design
Coordination of civil, structural, mechanical, electrical, controls, and safety systems into a cohesive and fully commissioned storage solution.
- Interface & Stakeholder Management
Acting as the central coordination point between client operations teams, contractors, and vendors to maintain technical, commercial, and programme alignment.
- Compressed Program Management
Delivery within a tightly constrained installation window, achieving completion ahead of critical harvest deadlines to safeguard business continuity during a forecast “on year.”
