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Home Case Study Purpose-Built Process Plant to Support Nexus Recycling Expansion

Purpose-Built Process Plant to Support Nexus Recycling Expansion

Industrial
Facility
Client
Nexus Recycling
project SNAPSHOT

Building type: Process Plant
Building size: 4,000m²
Sliding doors: 2 x 13m-high sliding doors
Delivery model: Design & Construct
Date: 2023

project summary
Todd Vains, Managing Director, partnered with AUSPAN to design and construct a purpose-built processing facility to support the expansion of Nexus Recycling. The 4,000m² facility was designed to support the extraction of approximately 97% of lead-acid battery materials, including acid, plastics and metallic lead, while providing increased processing capacity, improved machinery access and specialised infrastructure for the growing business.
The CHALLENGE

Expanding capacity within a constrained site

As Nexus Recycling continued to grow, Todd needed additional processing and storage capacity while maintaining safe, efficient workflows within a constrained site.

The specialised nature of the battery recycling facility created additional approval requirements, while limited available land and a significant site gradient added complexity to the design and construction process. Delivery was further impacted by COVID-19, with the Nexus management team based on the east coast.

Key requirements included:

  • Increase processing and extraction capacity
  • Maximise the use of limited available land
  • Navigate complex council approvals
  • Accommodate specialised safety and containment requirements
  • Improve machinery access and workflow

The Solution

A specialised facility designed around safety and efficiency

Working closely with Nexus Recycling, AUSPAN developed 3D concept drawings to clearly communicate the proposed solution before progressing to construction. The design maximised the available space, with retaining walls enabling the facility to extend close to the boundary.

Specialised civil works, including concrete plinths, bunded areas, lead containment and fire prevention features, were incorporated to support the recycling process. Two 13m-high sliding doors create 20m-wide openings, improving machinery access and manoeuvrability throughout the facility. Delivered by AUSPAN’s local WA teams, the project was managed from design through to completion.

Key features:

  • 4,000m² purpose-built processing facility
  • 2 x 13m-high sliding doors creating 20m-wide openings
  • Retaining walls to maximise available site space
  • Specialised fire prevention features
  • Concrete plinths, bunded areas and lead containment
  • Designed, manufactured and delivered in WA

the outcome

Built to support continued business growth

The completed facilities provide Nexus Recycling with increased capacity and purpose-built infrastructure to support more efficient processing, machinery movement and day-to-day workflows.

Specialised safety and containment features are integrated with durable construction and improved access, creating a practical facility designed around the specific requirements of the recycling operation.

For Todd, the project represents a long-term investment in the capability and future growth of Nexus Recycling, providing the infrastructure required to support the business as it continues to expand.

Customer Testimonial

What I enjoyed most about working with AUSPAN was the responsiveness, [and] the depth of knowledge of the staff. They’re a very good team to work with and so the overall experience was fantastic as a result.

Todd Vains
Managing Director,
Nexus Recycling
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