Pyrocal and Stahmann Webster advance sustainable agriculture with new carbonisation system in Leeton, NSW

Pyrocal has successfully installed a new Continuous Carbonisation System for Stahmann Webster at its Leeton facility in New South Wales, supporting the major nut producer’s sustainability and waste management goals.

Now operational, this new initiative is part of Stahmann Webster’s environmental, social and governance strategy to improve sustainability, manage waste and reduce greenhouse gas emissions.

Key details of the project include:

• Biochar Technology: The system uses Pyrocal’s CCT20 to transform waste shells into beneficial biochar.
• Capacity: The facility is designed to process up to 5,000 metric tonnes of walnut shell waste annually.
• Soil health: Used in Stahmann Webster’s orchards, the produced biochar will improve soil health by enhancing nutrient storage, increasing water holding capacity, boosting soil carbon content, and improving fertiliser efficiency.
• Carbon sequestration: The process is projected to sequester 3,000 metric tonnes of CO2 equivalents annually, supporting efforts to combat climate change.

Installation of the new system (including a continuous carbonisation hearth, thermal oxidiser, heat exchanger, emissions control systems, biochar handling and storage and integrated process automation) went ahead in mid-May 2026 with commissioning completed in June.

Pyrocal CEO Barry Croker said they are proud to be part of this forward-thinking project which will help Stahmann Webster achieve their broader goal of sustainable farming.

“Many other businesses with under‑utilised waste streams can benefit from this technology. If the material has a high fixed carbon content, we can trial it, scale it up and turn it into a positive outcome for the business, the environment and the surrounding community,” concluded Barry.

Stahmann Webster CEO Richard Sampson-Genest said the company expects the new facility to deliver multiple benefits for its orchards and broader sustainability strategy.

“In Australia, where soil quality can be variable and input costs continue to rise, biochar is emerging as a valuable tool for more sustainable farming,” he said. “By transforming what’s traditionally waste feedstocks into a valuable resource, this type of facility adds to those sustainability goals everybody’s looking for in a circular economy.”

With both the carbonisation process and soil amendment occurring entirely on site and no need to transport materials off‑farm, this project is a strong example of efficient, sustainable resource recovery and permanent carbon sequestration enabled by continuous carbonisation.

It also demonstrates how Pyrocal’s modular system can be seamlessly integrated into existing operations to support long‑term sustainability goals.

Pyrocal’s technology has evolved over a decade of improvement, optimisation and learning to help waste producing organisations solve their waste disposal challenges. If you’re interested in implementing a biochar project at your facility, please get in touch.