Wilmar Sugar processes about 50% of Australia’s raw sugar and requires a reliable locomotive fleet for this operation. The locomotive fleet is aging, as the last new locomotive was introduced to the fleet in 1991. As the crushing rates of the sugar mills have increased, the duty on the locomotive fleet has also increased, to ensure an adequate supply of cane to the sugar mills. Maintenance and minor improvements have been ongoing in the interim, to maintain adequate reliability in the locomotive fleet, but some of the fleet assets are now approaching, or are beyond economic repair. This is the case particularly with most of the 0-6-0 locomotives. In looking to procure new locomotives to replace the aging fleet, an assessment was conducted on the most appropriate locomotive type for Wilmar’s 1,600 km of track across four cane districts and eight sites. A locomotive of 24 to 32 t mass, based on a standardised chassis geometry and driveline, was the most appropriate whole-of-business decision, giving operational flexibility within the business. As Australia no longer manufactures locomotives suitable for the Australian sugar industry, a number of suppliers were approached globally for proposals. The proposals received were not considered practical in our remote environment, particularly with electrical, mechanical and control, maintenance and break-down support concerns. Wilmar Sugar has developed improvements for discrete elements of locomotives over time, using reliable components that are readily available. This knowledge has now been applied to manufacturing a locomotive from the sum of discrete elements already developed. This philosophy has the significant benefit that elements of locomotives are becoming the same or similar, which makes support for maintenance and break-downs less complex, as there is less variation and the technology is imbedded in the organisation. This reduces downtime and lifecycle ownership cost. This paper presents the development of the elements of the locomotive and the design process adopted in realising the 24–32 t locomotive to replace aging fleet assets.