Calix Limited
Taking Maddingley from pilot plant to commercial operation
Commissioning, Production, Quality and Site Leadership
- When
- 2012–2017
- Organisation
- Calix Limited
- Setting
- Maddingley operations
- Focus
- Scale-up and site leadership
The mandate
Build the operation around the technology
Commission the first full-scale flash calciner, then create the safety, quality, production and logistics systems required for reliable commercial supply.
Selected outcomes
Evidence of progress
- Zero
- Lost time injuries during site tenure
- ISO 9001
- Quality system developed and accredited
- $5m
- EBITDA reached within three years
- 15%+
- Sustained annual production growth
How the work was approached
From intent to operating capability
Commission the whole system
Furnace, calciner, filtration, heat recovery and powder handling were treated as connected operating systems rather than isolated equipment.
Make quality operational
Procedures, planning, testing and logistics were built around reliable delivery in full, on time and in specification.
Scale without weakening safety
Training, risk assessment and clear routines supported growth across operations, maintenance, research and new-product delivery.
Work delivered
What changed in practice
- Commissioned Calix's first full-scale flash calciner and supporting systems.
- Built the Quality Management System from the ground up.
- Implemented materials planning and international export infrastructure.
- Launched new products from research into commercial production.
Perspective
A new process becomes a business only when people can run it safely, customers can trust its output and the surrounding systems can carry growth.