Total Construction has been appointed as the design and construction partner for Stacked Farms’ fully automated indoor vertical farm at Melbourne Airport, marking a big step in the evolution of sustainable food production.
The project, with an investment of $150 million, has already received planning approvals, and construction began in January 2025.
The facility is set to cover 10,000 square metres and once completed, will be the world’s largest indoor vertical farm by output, producing 3.4 million kilograms of fresh herbs and leafy greens annually.
The project is scheduled to be completed by mid-2026.
As the designated partner for the design and construction of the project, Total Construction brings extensive experience in food and beverage facility development.
The company has been involved in the project from its inception, working under an Early Contractor Involvement (ECI) model, which allows for a collaborative and risk-managed approach to delivery.
Total Construction has been working closely with Stacked Farm and Melbourne Airport since 2023, refining the project’s design, approvals, and buildability.
This partnership has ensured the facility will be both efficient and scalable, offering a sustainable solution to meet the increasing demand for locally grown fresh produce.
By engaging early, Total Construction ensured the project isn’t only groundbreaking in scale and efficiency but also fully optimised for sustainability and performance.
“Our experience in delivering complex food and beverage facilities allows us to provide tailored engineering and construction solutions that support our clients’ technological and operational requirements,” said Rob Blythman group general manager, food and beverage at Total Construction.
Advanced pre-construction planning
Total Construction’s involvement from the early stages has been crucial in accelerating the project’s timeline. Key milestones during the pre-construction phase include:
The timeline for the Stacked Farm vertical farm project unfolded over several key stages, beginning in August 2023 and moving swiftly towards the commencement of construction in January 2025.
Initial design collaboration and feasibility assessments took place between August 2023 and April 2024, with Total Construction working closely with Stacked Farm to refine the project’s scope and design.
By October 2023, the first budgetary costing for the project was provided, and weekly steering meetings with Melbourne Airport were initiated to ensure alignment on the project’s progression. In January 2024, site investigations and due diligence were completed, confirming that the site was ready for development. This critical phase ensured that any potential issues were addressed before moving forward.
In February 2024, the planning permit was submitted, marking a milestone as this was the first time Melbourne Airport had seen a planning permit submitted before the board’s formal approval for the project. This proactive approach helped expedite the project’s approval process.
The APAM Board approved the project in March 2024, followed by Total Construction being issued a Letter of Intent to proceed with the design work.
The project reached another major milestone in May 2024, when the 100 per cent design finalisation was completed, and staged construction documentation was initiated. This signified the completion of the design phase and the start of detailed planning for the construction stage. In December 2024, Total Construction mobilised the site, with airport authority approval finalised, setting the stage for the physical development to begin.
Finally, in January 2025, construction officially began, marking the start of the next phase in bringing the world’s largest indoor vertical farm (by volume) to life at Melbourne Airport. This careful and methodical timeline ensured that each step was completed efficiently, paving the way for a successful project delivery.
The Stacked Farms vertical farm project will set a global benchmark for high-tech farming, featuring advanced technology and sustainable practices.
Key innovations
This new facility will have several standout features including AI-driven operations. It will be automated, with 25 proprietary robotic systems managing key processes such as seeding, germination, and harvesting This technology ensures precise, efficient farming with minimal human intervention, increasing productivity while reducing the need for manual labour.
In addition to automation, the facility is designed with energy efficiency in mind. The lighting systems used in the farm will be 47 per cent more energy-efficient than traditional farming setups, lowering the farm’s energy consumption. This focus on energy efficiency is just one aspect of the farm’s commitment to sustainability, as it will also implement a zero-waste water system.
This system will recycle and reuse water throughout the farming process, ensuring minimal waste.
The farm’s ability to produce crops year-round is supported by a climate-controlled environment, which ensures consistent conditions for growth regardless of the external weather.
This climate control allows for continuous, reliable crop production, a crucial factor in meeting demand and maintaining supply throughout the year.
Labour efficiency is another area where the facility excels. Unlike traditional farms that often require large teams to manage operations, Stacked Farm will only need 15 highly skilled staff to run the entire operation.
This streamlined workforce is made possible by the advanced technology and automation systems in place, enabling the farm to operate more efficiently than conventional farming methods.
Finally, the farm will see faster crop cycles compared to traditional farming.
Crops will be ready for harvest in just 16 to 31 days, a reduction from the typical 45 to 80 days required for crops grown using conventional methods.
The accelerated cycle allows the farm to produce more crops in less time, further improving efficiency and sustainability.
Total Construction’s expertise in high-performance food and beverage infrastructure positions the company as a leader in delivering innovative, sustainable, and future-proof developments.
This project is another milestone in Total Construction’s history of successful food and beverage projects, showcasing its in-house expertise in process engineering, design, and construction management.
Once completed, Stacked Farm Melbourne will be the first large-scale indoor vertical farm located in an airport precinct in the Southern Hemisphere.
The facility will not only demonstrate the power of advanced engineering and sustainable practices but will also serve as a model for future vertical farming projects worldwide.
