William Scott
With capacity to house an Airbus A380, the fruit packing shed built for Victorian-based Red Rich Fruits remains a milestone in Australia’s horticultural sector. At the time of its construction in 2018–19, it was the country’s largest clear span fruit packing shed, enabling Red Rich Fruits to double production output and significantly improve efficiencies.
Designed and constructed by Entegra, the facility broke new ground with its clear span of 80 metres—larger than the Airbus A380’s wingspan of 79.75 metres. With no internal columns or posts, the shed provides unimpeded space for vehicle movement and logistics, a feature that was revolutionary for the industry at the time.
Since this landmark project, Entegra has continued to push boundaries, establishing itself as a leader in designing and constructing massive clear span structures across diverse industries, including commercial, agricultural, and aviation. What was once a bold engineering challenge has now become part of Entegra’s DNA.
The Red Rich Fruits project catalysed Entegra’s expansion of its capabilities, including innovations in manufacturing, design, and engineering. Today, the company regularly undertakes large-scale projects that rival and surpass this Airbus-sized structure.
A Groundbreaking Shed for Its Time
The shed at Red Rich Fruits was a game-changer for the horticultural sector, incorporating the latest technologies in conveyor, grading, packing, and coolroom systems to boost productivity.
Situated on the Napoleone family’s 400-hectare Yarra Valley property, the facility replaced a smaller packing centre that had been outgrown. Standing nine metres high (to the eaves) and spanning 128m by 80m, with 10m canopies on two sides, it provided almost 2,200 square metres of unimpeded floorspace.
Engineering Innovation Leads the Way
Entegra’s projects team, which is now led by Justin Scott, was tasked with achieving the largest clear span area possible. At the time, Entegra had built sheds with a maximum clear span of 60m. Extending this to 80m required innovative design, advanced manufacturing systems, and new equipment.
“We had to break new ground in architectural design and our own manufacturing processes,” Mr Scott said.
“This project allowed us to establish a capability we have since built upon, enabling us to deliver even larger and more complex projects today.”
Entegra engineered 2.7m deep trusses for this project—double the size of anything it had fabricated before—using cutting-edge technologies at its manufacturing plant.
A Benchmark for Efficiency
The packing shed’s ‘passive box’ design was a standout feature, maximising energy efficiency with capacity for solar loading of 650kW to 1000kW on a 10,000-square-metre roof and the potential to harvest 100% of rainfall for on-site use.
Red Rich Fruits’ director Michael Napoleone highlighted the operational benefits:
“The new shed allowed us to double our throughput to around 400 tonnes of apples and pears per week while significantly improving grading and cold storage control systems to maintain product quality and longevity.”
With advanced fruit grading technologies, including photographic imagery systems to identify faults inside the fruit, the facility set new standards for productivity and product quality in the horticultural industry.
The Legacy of Red Rich Fruits’ Airbus-Sized Shed
For Entegra, the Red Rich Fruits project represented more than just a milestone; it became a stepping stone to even greater achievements. Managing Director Laurie McCalman reflected on the impact:
“This packing shed pushed the boundaries for us in design and engineering. It was a challenge that we embraced and have built on ever since. Today, we are delivering projects of even larger scale across multiple sectors.”
Entegra’s appetite for innovation continues to fuel its growth. From warehouses and distribution centres to aviation hangars and steel structures for farming, the company has established itself as Australia’s go-to provider for large-scale, purpose-built facilities.
“We’re always looking to outdo our last project. That drive to innovate ensures that our clients not only meet but exceed their operational goals.”
Review Your Infrastructure Requirements Today
Could your business benefit from increased productivity and operational efficiency with a Entegra designed clear span structure?
Entegra’s team of experts works closely with you to deliver purpose-built solutions tailored to your unique needs.
Call us today on 1300 296 206 or visit www.entegra.com.au to get started.
