Autumn is a busy time for the almond industry.
Orchards are a hive of activity, as the crop is harvested.
Processors are also hard at work hulling and shelling - work that will continue through winter and sometimes into spring.
Kellie Hollingworth caught up with some of the processors, to find out about upgrades and other initiatives that are set to enhance their operations in 2025 and beyond.
General manager of Costa Brothers Hullers and Shellers Claire Durant says the company has invested in a number of improvements ahead of the 2025 season.
A REVAMPED pre-clean area, a new colour sorter, telehandlers, generator and worker accommodation are some of the 2025 improvements for Costa Brothers Hullers and Shellers at Swan Reach. The Fenix 3U Vision is the first four-colour, singlecamera optical sorter developed.
The machine manufactured in Italy is capable of identifying defects in similar colour products by simultaneously using red green blue (RGB), high resolution multispectral cameras shortwave infrared (SWIR) spectrum and infrared (IR) optical systems. The company has also poured a substantial amount of concrete in the pre-clean area and reconfigured some of the bays to make them larger. New telehandlers have been acquired for the 2025 season, along with a new generator to run the cracking plant.
The general manager of Costa Brothers Hullers and Shellers, Claire Durant, said a record 10,000 tonnes was processed in 2024 and a similar volume is expected to be hulled and shelled this year, with a focus on quality.
The plant will operate 24 hours a day, five days per week.
There isn’t a need to run seven days per week, but this can change if required.
The two-day rest period also enables any urgent maintenance to be done on weekends. The hullers and shellers is staffed by 10 permanent workers and 10 casuals.
The company uses the Pacific Australia Labor Mobility (PALM) scheme for its casual workforce and this season a team from Samoa is returning for their second year.
ABOVE: For the second year, Costa Brothers Hullers and Shellers have hired a group of Samoan workers on the PALM scheme to process almonds.
LEFT: The general manager of Costa Brothers Hullers and Shellers, Claire Durant, with one of the new telehandlers.
“While they are here, they work hard, love their money because it’s so much more than they could make at home and it enables them to provide for their families,” she said.
Last season the Samoan workers commuted to Swan Reach from Blanchetown, which is a 20-minute drive each way.
Costa Brothers Hullers and Shellers is now building accommodation on their property at Swan Reach and this should be ready by April.
“The village will initially accommodate 15 people in individual rooms but it also includes a shared common area with a lounge and kitchen, along with bathroom and laundry facilities,” she said.
The company kicked off its processing by hulling and shelling organic almonds in February, before moving to Non Pareil, Independence and Carina, followed by the remaining varieties.
They aim to have finished the season by mid August, weather dependant.
Last year the majority of the hull and shell was purchased by feedlots, with most trucked to Queensland, but a small volume also stayed in South Australia.
“It was very different to 2023 when there was no demand for hull and shell, as seasonal conditions were good,” Claire said.
Feedlot demand is expected to be strong again this year. The Costas have been growing and processing almonds for more than 50 years.
The original five acre orchard was at the back of the family’s vineyard in Angle Vale and Don Costa’s brother John also had a 20-acre block next door.
In 1977 Don established a commercial almond processing facility in Angle Vale which operated until 2016. The family acquired an established orchard in Swan Reach SA in 2007.
Don remains as a board member after his retirement in 2016.
In 2012-2014 Don’s sons Michael, Tony and Phillip began planning and construction of a new 5500 square metre hulling and shelling facility at Swan Reach. In 2017 the plant was operational, and all processing was relocated to Swan Reach.
In 2024 Costa Brothers constructed a 3000 square metre facility to be used for a new Activated Carbon Project, scheduled for 2026 installation.